U.S. patent number 9,633,765 [Application Number 14/812,227] was granted by the patent office on 2017-04-25 for coaxial cable device having a helical outer conductor and method for effecting weld connectivity.
This patent grant is currently assigned to John Mezzalingua Associates, LLC. The grantee listed for this patent is John Mezzalingua Associates, LLC. Invention is credited to Ian J. Baker, Noah P. Montena, Christopher P. Natoli, Gerhard Refle, Werner Wild.
United States Patent |
9,633,765 |
Natoli , et al. |
April 25, 2017 |
Coaxial cable device having a helical outer conductor and method
for effecting weld connectivity
Abstract
A jumper cable having an end prepared for connecting to a
coupling assembly. The prepared end includes an inner conductor, an
outer conductor having a helical outer surface contour, and a
dielectric core disposed between the inner and outer conductors. A
weld washer: (i) threadably engages the helical outer surface
contour of the outer conductor, (iii) receives a deformed edge of
the outer conductor through an opening in the washer, and (iv) is
penetration welded to deformed edge of the outer conductor.
Operationally, the face of the weld washer augments the flow of
electrical current to electrically ground the outer conductor to
the coaxial cable connector.
Inventors: |
Natoli; Christopher P.
(Baldwinsville, NY), Wild; Werner (Buttenwiesen,
DE), Baker; Ian J. (Baldwinsville, NY), Montena;
Noah P. (Syracuse, NY), Refle; Gerhard (Heretsried,
DE) |
Applicant: |
Name |
City |
State |
Country |
Type |
John Mezzalingua Associates, LLC |
Liverpool |
NY |
US |
|
|
Assignee: |
John Mezzalingua Associates,
LLC (Liverpool, NY)
|
Family
ID: |
54539073 |
Appl.
No.: |
14/812,227 |
Filed: |
July 29, 2015 |
Prior Publication Data
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Document
Identifier |
Publication Date |
|
US 20150332809 A1 |
Nov 19, 2015 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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14137316 |
Dec 20, 2013 |
9312609 |
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14052539 |
Oct 11, 2013 |
9384872 |
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61712496 |
Oct 11, 2012 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01B
11/18 (20130101); H01R 4/183 (20130101); H01R
4/029 (20130101); H01R 9/05 (20130101); H01R
24/564 (20130101); H01R 13/5205 (20130101); Y10T
29/49123 (20150115); Y10T 29/49181 (20150115) |
Current International
Class: |
H02G
15/02 (20060101); H01R 9/05 (20060101); H01B
11/18 (20060101); H01R 4/02 (20060101); H01R
4/18 (20060101); H01R 13/52 (20060101); H01R
24/56 (20110101) |
Field of
Search: |
;174/84R,88R,88C,102R,108,109 ;439/578,582-585 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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2 219 267 |
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Feb 2009 |
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EP |
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2219267 |
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Feb 2009 |
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EP |
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Other References
USPTO (ISA/US), International Search Report an Written Opinion of
the ISA from PCT/US2013/064682 dated Mar. 11, 2014 (13 pgs.). cited
by applicant.
|
Primary Examiner: Mayo, III; William H
Attorney, Agent or Firm: Barclay Damon, LLP
Parent Case Text
PRIORITY CLAIM
This application is a continuation-in-part of, and claims the
benefit and priority of U.S. patent application Ser. No.
14/137,316, filed Dec. 20, 2013, which is a continuation-in-part
of, and claims the benefit and priority of, U.S. patent application
Ser. No. 14/052,539, filed on Oct. 11, 2013, which is a
Non-Provisional of, and claims the benefit and priority of, U.S.
Provisional Patent Application Ser. No. 61/712,496, filed on Oct.
11, 2012.
INCORPORATION BY REFERENCE
The entire contents of the following applications are hereby
incorporated by reference: (a) U.S. patent application Ser. No.
14/137,316, filed Dec. 20, 2013 (b) U.S. patent application Ser.
No. 14/052,539, filed on Oct. 11, 2013; (c) U.S. Provisional Patent
Application Ser. No. 61/712,496, filed on Oct. 11, 2012; (d) U.S.
patent application Ser. No. 13/661,962, filed on Oct. 26, 2012; (e)
U.S. patent application Ser. No. 13/661,912, filed on Oct. 26,
2012; (f) U.S. patent application Ser. No. 13/784,499, filed on
Mar. 4, 2013; and (g) U.S. patent application Ser. No. 13/869,295,
filed on Apr. 24, 2013.
Claims
The following is claimed:
1. A jumper cable having an end prepared for connecting to a
connector coupling assembly, the prepared end including an inner
conductor, an outer conductor and a dielectric core disposed
therebetween, the outer conductor having a helical outer surface
contour, the prepared end comprising: a weld washer split along a
radial line for threadably engaging the helical outer surface
contour of the outer conductor, the weld washer defining an angle
relative to the radial line, receiving a deformed edge of the outer
conductor through an opening in the washer, and defining an
anti-rotation surface, the deformed edge of the outer conductor
being penetration welded to the weld washer, and an adaptor ring
including a ferrule support ring and a ferrule cap; the ferrule
support ring disposed on one side of the weld washer and defining a
surface engaging the anti-rotation surface of the weld washer; the
ferrule cap disposed on the other side of the weld washer, the
conductive being press fit to a peripheral surface of the ferrule
supporting to secure the weld washer therebetween; wherein the
coaxial cable connector is affixed to a peripheral surface of the
adaptor ring and a face surface of the weld washer augments the
flow of electrical current to electrically ground the outer
conductor to the coaxial cable connector.
2. A method for fabricating a jumper cable having a connector
coupling assembly attached to a prepared end of a coaxial cable,
the prepared end including an inner conductor, an outer conductor
and a dielectric core disposed therebetween, the outer conductor
having a helical outer surface contour, the method comprising the
steps of: splitting a washer along a radial line to define a pair
of opposed radial edges along the radial line, the washer having
opening and a thickness dimension orthogonal to the washer opening,
stamping the washer such that the radial edges are out-of-plane and
the washer defines a lead angle corresponding to the lead angle of
the helical outer surface contour of the outer conductor;
threadably engaging the split washer onto an end of the helical
outer surface contour of the outer conductor such that the end of
the outer conductor is proud relative to the washer opening;
flaring the proud end around the inner edges of the washer opening;
and welding the flared end of the outer conductor to the split
washer; wherein a face of the split washer augments the flow of
electrical current to electrically ground the outer conductor to
the coaxial cable connector.
3. The method according to claim 2 wherein the step of welding the
flared end of the outer conductor to the split washer comprises
penetration welding.
4. The method of claim 3 wherein the step of penetration welding
includes contiguously spot welding the folds of the helical outer
conductor into the weld washer around the edges of the washer
opening.
5. The method according to claim 2 wherein the step of threadably
engaging an end of the split washer onto an end of the outer
conductor comprises the step of threading the split washer onto the
end such that at least two helical corrugations of the helical
outer surface contour extend beyond the washer opening.
6. The method according to claim 2 wherein the step of flaring the
proud end around the inner edges of the washer opening comprises
the step of producing a concave surface along a radially inboard
surface of the split washer to effect inward reflection of the
penetration weld energy away from a weld energy source.
7. The method according to claim 2 wherein the step of flaring the
proud end around the inner edges of the washer opening comprises
the step of deforming the weld washer such that a radially inboard
surface thereof forms a frustacone to define an angle
.degree..theta. indicative of the reflection angle of the
penetration weld relative to a plane orthogonal to the elongate
axis of the coaxial cable, the angle .theta. being greater than at
least about ten degrees (10.degree.) relative to the orthogonal
plane to direct reflected weld energy away from its source.
8. The method according to claim 2 wherein the step of flaring the
proud end around the inner edges of the washer opening comprises
the step of folding the end of the helical outer conductor around
the opening of the washer to achieve a thickness dimension equal to
about the thickness dimension of the weld washer.
9. A jumper cable having an end prepared for connecting to a
connector coupling assembly, the prepared end including an inner
conductor, an outer conductor and a dielectric core disposed
therebetween, the outer conductor having a helical outer surface
contour, the jumper cable, comprising: a weld washer configured to
threadably engage the helical outer surface contour of the outer
conductor, the weld washer receiving a deformed edge of the outer
conductor through an opening in the washer, the deformed edge of
the outer conductor being penetration welded to the weld washer,
wherein a face of the weld washer augments the flow of electrical
current to electrically ground the outer conductor to the coaxial
cable connector.
10. The jumper cable of claim 9 further comprising an adaptor ring
including: a ferrule support ring disposed on one side of the weld
washer; and a ferrule cap disposed on the other side of the weld
washer, the conductive cap being press fit to a peripheral surface
of the ferrule support ring to secure the weld washer
therebetween.
11. The jumper cable of claim 9 wherein the deformed edge increases
the thickness by at least a factor of two (2) to ensure a
sufficient weld thickness to penetration weld the edge of the outer
conductor.
12. The jumper cable of claim 9 wherein the deformed edge increases
the thickness by at least a factor of three (3) to ensure a
sufficient weld thickness to penetration weld the edge of the outer
conductor.
13. The jumper cable of claim 9 wherein the weld washer defines a
thickness dimension within a range of between about twenty-five
thousandths inches (0.025'') to about one-hundred thousandths
inches (0.100'').
14. The jumper cable of claim 13 wherein the helical outer
conductor is deformed by folding the edge around the opening of the
washer, the outer conductor being folded to achieve a thickness
dimension equal to about the thickness dimension of the weld
washer.
15. The jumper cable of claim 9 wherein the adaptor ring mates with
the coaxial cable connector and defines a first anti-rotation
surface, and wherein the weld washer defines a second anti-rotation
surface, the first and second anti-rotation surfaces engaging to
prohibit rotation of the connector about an elongate axis of the
coaxial cable.
16. The jumper cable of claim 15 wherein the second anti-rotation
surface is defined by an edge of the weld washer, the edge
splitting the washer for threadably engaging the washer with the
outer conductor.
17. The jumper cable of claim 9 wherein the weld surface defines a
surface configured to reflect penetration weld energy away from a
weld energy source.
18. The jumper cable of claim 17 wherein the weld washer defines a
concave surface to cause inward reflection of the penetration weld
energy.
19. The jumper cable of claim 17 wherein the weld washer is severed
along a radial line.
20. The jumper cable of claim 17 wherein the weld washer is severed
along a tangential line.
21. The jumper cable of claim 9 wherein a radial inboard portion of
the weld washer forms a frustacone defining an angle indicative of
the reflection angle of the penetration weld relative to a plane
orthogonal to the elongate axis of the coaxial cable, the angle
being greater than at least about ten degrees (10) relative to the
orthogonal plane.
22. The jumper cable of claim 9 wherein the weld washer comprises
an oxygen-free copper material which is weld compatible with the
outer conductor of the coaxial cable.
23. The jumper cable of claim 9 wherein the penetration weld
includes a plurality of contiguous spot welds equidistant from, and
forming a circle about, the center of the inner conductor.
Description
BACKGROUND
Coaxial cables are typically connected to interface ports, or
corresponding connectors, for the operation of various electronic
devices, such as cellular communications towers. Many coaxial
cables are installed on cellular towers, outdoors or in harsh
environments, subjecting the cables to wind, vibration and other
elements. The typical coaxial cable connector has several
interconnected, internal parts. Over time, due to the environmental
factors and other causes, these internal parts can become loose or
lose mechanical contact with each other. As a result, the
electronic devices connected to the cables can undergo a decrease
or loss in performance.
For example, the loose internal parts can cause undesirable levels
of passive intermodulation (PIM) which, in turn, can impair the
performance of the electronic devices. PIM can occur when signals
at two or more frequencies mix with each other in a non-linear
manner to produce spurious signals. The spurious signals can
interfere with, or otherwise disrupt, the proper operation of the
electronic devices.
Spurious signals can develop and, PIM performance can suffer
wherever components in the coaxial cable system connect. In
particular, when the interface between connecting components
becomes loose, shifts and/or moves, micro-arcing can occur and
disrupt signal transmission. Consequently, wherever possible, it is
desirable to effect an immobile connection between components to
prevent rotational or axial displacement, i.e., rubbing, along a
mating interface.
Where the coaxial cable is employed on a cellular tower, for
example, unacceptably high levels of PIM in terminal sections of
the coaxial cable, and resulting interfering RF signals, can
disrupt communication between sensitive receiver and transmitter
equipment on the tower and lower-powered cellular devices.
Disrupted communication can result in dropped calls or severely
limited data rates, for example, which can result in dissatisfied
customers and customer churn.
Therefore, there is a need to overcome, or otherwise lessen the
effects of, the disadvantages and shortcomings described above.
SUMMARY
In one embodiment, a jumper cable is provided having an end
prepared for connecting to a coupling assembly. The prepared end
includes an inner conductor, an outer conductor having a helical
outer surface contour, and a dielectric core disposed between the
inner and outer conductors. Specifically, a weld washer: (i)
threadably engages the helical outer surface contour of the outer
conductor, (ii) receives a deformed edge of the outer conductor
through an opening in the washer, and (iii) is penetration welded
to deformed edge of the outer conductor. Operationally, the face of
the weld washer augments the flow of electrical current to
electrically ground the outer conductor to the coaxial cable
connector.
In another embodiment, the weld washer is cut or severed along a
radial, tangential or chord line to facilitate engagement with the
helical outer surface contour of the outer conductor. In another
embodiment, the weld washer is configured to reflect penetration
weld energy away from the weld energy source. And, in another
embodiment, the surface of the weld washer is concave to reflect
penetration weld energy inwardly.
In one embodiment, the coaxial cable assembly or coaxial cable
device includes a coaxial cable having an inner conductor, an outer
conductor, an inner conductor engager, a compressor configured to
cooperate with at least part of the inner conductor engager, and an
outer conductor engager configured receive at least part of the
outer conductor. The outer conductor engager is welded to the
received part of the outer conductor.
In one embodiment, the inner conductor engager is configured to
receive at least part of the inner conductor. In another
embodiment, the coaxial outer conductor has a corrugated shape
defining: (a) a plurality of peaks and valleys; and (b) an
intermediate section extending from each valley to each peak. The
outer conductor engager is welded to one of the intermediate
sections. In one embodiment, the intermediate section of the outer
conductor extends in a first plane, the outer conductor engager has
a conductor engagement surface extending in a second plane which is
substantially parallel to the first plane.
In another embodiment, the coaxial cable device has a compression
driver. The compression driver defines an opening configured to
receive the inner conductor. In one embodiment, the coaxial cable
device has a body. In another embodiment, the coaxial cable device
has a coupler rotatably coupled to the body.
In one embodiment, the coaxial cable device includes a coaxial
cable having an inner conductor and an outer conductor, an inner
conductor engager having a side wall, and an outer conductor
engager welded to at least part of the outer conductor. The side
wall includes: (a) a receiving edge configured to receive at least
part of the inner conductor; and (b) at least one additional edge
defining at least one opening. The additional edge is welded to the
received part of the inner conductor.
In another embodiment, the side wall has a circumference and a
length. The opening has a longitudinal axis extending along at
least part of the length of the side wall. In another embodiment,
the opening has a longitudinal axis extending along part of the
circumference of the side wall. In one embodiment, the opening has
one or more of the following shapes: a circle, an oval, a square, a
rectangle, a triangle, a polygon, a shape comprising part of a
polygon and at least one curved line, and a shape comprising a
plurality of curved lines. In another embodiment, the additional
edge comprises a length which is greater than a circumference of
the inner conductor.
In one embodiment, the side wall defines a plurality of additional
edges, and each edge defines an opening. Each of the additional
edges has a length, width and a surface area. The additional edges
are welded to the received part of the inner conductor. The sum of
the lengths of the additional edges is greater than the
circumference of the inner conductor.
In one embodiment, the opening provides the inner conductor engager
with an asymmetric configuration. In another embodiment, the inner
conductor has an inner portion comprised of an inner material type.
The inner conductor also has an outer portion comprised of a
different, outer material type. After the one or more additional
edges are welded to the received part, the outer portion of the
inner conductor excludes the inner material type.
In one embodiment, the outer conductor comprises a corrugated shape
defining: (a) a plurality of peaks and valleys; and (b) an
intermediate section extending from each valley to each peak. The
outer conductor engager is welded to one of the intermediate
sections.
In one embodiment: (a) at least one of the intermediate sections of
the outer conductor extends in a first plane; and (b) the outer
conductor engager has a conductor engagement surface extending in
second plane which is substantially parallel to the first
plane.
In another embodiment, the a coaxial cable device is fabricated or
manufactured through a process which involves the following steps:
(a) inserting at least part of an outer conductor of a coaxial
cable into an opening defined by an outer conductor receiver,
wherein, after the insertion, the outer conductor receiver has a
receiver weldable section which is adjacent to a conductor weldable
section of the outer conductor; (b) directing energy toward the
receiver weldable section and/or the conductor weldable section,
wherein the energy is operable to weldably connect the receiver
weldable section to the conductor weldable section; and (c)
engaging an inner conductor of the coaxial cable with an inner
conductor engager.
In one embodiment, the process includes inserting at least part of
the inner conductor into a second opening defined by the inner
conductor engager. In another embodiment, the outer conductor has a
corrugated shape. The corrugated shape defines: (a) a plurality of
peaks and valleys; and (b) an intermediate section extending from
each valley to each peak. The conductor weldable section has at
least part of one of the intermediate sections.
In another embodiment: (a) at least one of the intermediate
sections of the outer conductor extends in a first plane; and (b)
the receiver weldable section extends in second plane which is
substantially parallel to the first plane. In one embodiment, the
process includes: (a) inserting at least part of the inner
conductor engager within a body; and (b) attaching a rotatable
coupler to the body.
In one embodiment, the coaxial cable assembly or device has a
coaxial cable including an inner conductor and an outer conductor.
The inner conductor has a surface which is deformable to define a
recessed space. The device also has an inner conductor engager
which is engaged with the inner conductor. Part of the inner
conductor engager is deformed to fit within the recessed space.
Also, the device has an outer conductor engager welded to the outer
conductor.
In one embodiment, the outer conductor engager is configured to
receive a portion of the outer conductor, and the outer conductor
engager is welded to the received portion of the outer conductor.
In another embodiment, the coaxial cable device has a jacket
surrounding the outer conductor. The outer conductor engager has:
(a) a conductor engagement portion engaged with the outer
conductor; and (b) a jacket engagement portion engaged with the
jacket. In yet another embodiment, the coaxial cable has a jacket
surrounding the outer conductor. The coaxial cable device has a
jacket engager engaged with the jacket, and the jacket engager
mates with the outer conductor engager. In still another
embodiment, the coaxial cable device has a strain relief device.
The outer conductor engager has a strain relief engagement portion
engaged with the strain relief device.
In another embodiment, the outer conductor engager has: (a) an
inner seal holder which holds an outer conduct seal; and (b) an
outer seal holder which holds a strain relief device seal. In yet
another embodiment, a portion of the outer conductor has an inner
surface and an outer surface opposite of the inner surface. The
coaxial cable device has an outer conductor support configured to
engage the inner surface while the outer conductor engager is
engaged with the outer surface. In one embodiment, the inner
conductor engager is crimped to the inner conductor.
In another embodiment, the inner conductor has a first wall which
partially defines the recessed space. The part of the inner
conductor engager has a second wall. The first and second walls are
engaged with each other through an engagement, such as a crimped
engagement, a frictional engagement, a mating engagement or an
interlocked engagement.
In one embodiment, the coaxial cable assembly or device includes:
(a) a coaxial cable having an inner conductor and an outer
conductor; (b) an inner conductor engager crimped to the inner
conductor; and (c) an outer conductor engager welded to the outer
conductor.
In one embodiment, the coaxial cable device is manufactured through
a process involving the following steps: (a) supporting a coaxial
cable which has an inner conductor and an outer conductor; (b)
welding an outer conductor engager to the outer conductor; (c)
supporting an inner conductor engager, wherein the inner conductor
engager is configured to receive a portion of the inner conductor;
(d) inserting the portion of the inner conductor into the inner
conductor engager; and (e) applying a force to the inner conductor
engager when the portion is inserted within the inner conductor
engager, wherein the force causes the inner conductor engager and
the portion to deform.
In one embodiment, the process includes engaging the outer
conductor engager with the jacket. In another embodiment, the
process includes engaging a jacket engager engaged with the jacket,
wherein the jacket engager mates with the outer conductor engager.
In yet another embodiment, the process includes engaging the strain
relief device with a strain relief device engagement portion of the
outer conductor engager.
The foregoing and other features of construction and operation will
be more readily understood and fully appreciated from the following
detailed disclosure, taken in conjunction with accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Some of the embodiments will be described in detail, with reference
to the following figures, wherein like designations denote like
members, wherein:
FIG. 1 depicts a cross-sectional view of a first embodiment of a
coaxial cable connector.
FIG. 2A depicts a perspective view of a first embodiment of a
coaxial cable.
FIG. 2B depicts a perspective view of a second embodiment of a
coaxial cable.
FIG. 2C depicts a perspective view of a third embodiment of a
coaxial cable.
FIG. 3 depicts a cross-sectional view of a first embodiment of an
electrical contact.
FIG. 4 depicts a cross-sectional view of a first embodiment of a
connector body.
FIG. 5 depicts a cross-sectional view of an embodiment of a first
insulator body.
FIG. 6 depicts a cross-sectional view of an embodiment of a second
insulator body.
FIG. 7 depicts a cross-sectional view of the first embodiment of
the coaxial cable connector having a first and second weld.
FIG. 8A depicts a cross-sectional view of the first embodiment of
the electrical contact welded to a center conductor of a coaxial
cable.
FIG. 8B depicts a top view of the first embodiment of the
electrical contact welded to a center conductor of a coaxial
cable.
FIG. 9 depicts a top view of the first embodiment of the connector
body welded to an outer conductor of the coaxial cable
connector.
FIG. 10 depicts a cross-sectional view of a second embodiment of a
coaxial cable connector.
FIG. 11 depicts a cross-sectional view of a fourth embodiment of a
coaxial cable.
FIG. 12 depicts a cross-sectional view of a second embodiment of a
connector body.
FIG. 13 depicts a top view of a second embodiment of the electrical
contact welded to a center conductor of a coaxial cable.
FIG. 14A depicts a cross-sectional view of one embodiment of a
welding component.
FIG. 14B depicts a top view of an embodiment of a welding component
welded to an outer conductor of a coaxial cable.
FIG. 14C depicts a cross-sectional view of an embodiment of the
welding component welded to the outer conductor of the coaxial
cable.
FIG. 15 depicts a cross-sectional view of a third embodiment of a
coaxial cable connector.
FIG. 16 is a schematic diagram illustrating one embodiment of
coaxial cable devices coupled to a cellular tower and cellular base
station.
FIG. 17 is an isometric view of one embodiment of the coaxial cable
device.
FIG. 18 is a top isometric view of one embodiment of the coaxial
cable device.
FIG. 19 is a top isometric, exploded view of the components of one
embodiment of the coaxial cable device.
FIG. 20 is a side isometric view of one embodiment of the coaxial
cable device, illustrating the visible parts with the boot and
connector body removed.
FIG. 21 is a side, cross-sectional view of one embodiment of the
coaxial cable device.
FIG. 22 is an enlarged, side cross-sectional view of one embodiment
of the coaxial cable device.
FIG. 23 is an enlarged, isometric cross-sectional view of one
embodiment of the coaxial cable device.
FIG. 24 is an enlarged, side cross-sectional view of one embodiment
of the coaxial cable device, illustrating the arrangement before
compression of the inner conductor.
FIG. 25 is an enlarged, side cross-sectional view of one embodiment
of the coaxial cable device, illustrating the arrangement after
compression of the inner conductor.
FIG. 26 is a side isometric view of one embodiment of the boot of
the coaxial cable device.
FIG. 27 is a side isometric view of one embodiment of the seal of
the coaxial cable device.
FIG. 28 is a front isometric view of one embodiment of the outer
conductor engager of the coaxial cable device.
FIG. 29 is a rear isometric view of the outer conductor engager of
FIG. 28.
FIG. 30 is a side elevation view of the outer conductor engager of
FIG. 28.
FIG. 31 is a side cross-sectional view of the outer conductor
engager of FIG. 28.
FIG. 32 is a rear isometric view of one embodiment of the
compression driver of the coaxial cable device.
FIG. 33 is a front isometric view of the compression driver of FIG.
32.
FIG. 34 is a top, isometric, cross-sectional view of the
compression driver of FIG. 32.
FIG. 35 is a side isometric view of one embodiment of the inner
conductor engager of the coaxial cable device.
FIG. 36 is a rear isometric view of the inner conductor engager of
FIG. 35.
FIG. 37 is a side, cross-sectional view of the inner conductor
engager of FIG. 35.
FIG. 38 is a rear isometric view of one embodiment of the
compressor of the coaxial cable device.
FIG. 39 is a front, side isometric view of the compressor of FIG.
38.
FIG. 40 is a side, cross-sectional view of the compressor of FIG.
38.
FIG. 41 is a rear, isometric view of one embodiment of the
connector body of the coaxial cable device.
FIG. 42 is a front, isometric view of the connector body of FIG.
41.
FIG. 43 is a side elevation view of the connector body of FIG.
41.
FIG. 44 is a side cross-sectional view of the connector body of
FIG. 41.
FIG. 45 is a front, isometric view of one embodiment of the cable
of the coaxial cable device, illustrating the shape of the outer
conduct before folding or hemming.
FIG. 46 is a front, isometric view of the cable of FIG. 45,
illustrating the shape of the outer conduct after folding or
hemming.
FIG. 47 is a front, isometric view of one embodiment of the cable
shown connected to the compression driver of the coaxial cable
device.
FIG. 48 is a top, isometric, cross-sectional view of one embodiment
of the cable shown connected to the compression driver of the
coaxial cable device.
FIG. 49 is a top, isometric, cross-sectional view of one embodiment
of the cable shown connected to the outer conductor engager and
compression driver of the coaxial cable device.
FIG. 50 is a top, isometric, cross-sectional view of one embodiment
of the cable shown connected to the outer conductor, illustrating
the weld interfaces and hem of the outer conductor engager.
FIG. 51 is a side, isometric, cross-sectional view of one
embodiment of the cable shown connected to the outer conductor,
illustrating the weld interfaces and hem of the outer conductor
engager.
FIG. 52 is a front, side, isometric, cross-sectional view of one
embodiment of the cable shown connected to the outer conductor,
illustrating the weld interfaces, the hem of the outer conductor
engager and the weld energy streams.
FIG. 53 is a side, isometric, cross-sectional view of one
embodiment of the cable shown connected to the outer conductor,
illustrating the weld interfaces, the hem of the outer conductor
engager and the weld energy streams.
FIG. 54 is a side isometric view of one embodiment of the inner
conductor and inner conductor engager of the coaxial cable
device.
FIG. 54 is a side isometric view of another embodiment of the inner
conductor and inner conductor engager of the coaxial cable
device.
FIG. 55 is a side isometric view of yet another embodiment of the
inner conductor and inner conductor engager of the coaxial cable
device.
FIG. 56 is a side isometric view of still another embodiment of the
inner conductor and inner conductor engager of the coaxial cable
device.
FIG. 57 is a side isometric view of a further embodiment of the
inner conductor and inner conductor engager of the coaxial cable
device.
FIG. 58 is a side isometric view of an additional embodiment of the
inner conductor and inner conductor engager of the coaxial cable
device.
FIG. 59 is a side isometric, cross-sectional view of one embodiment
of the coaxial cable device.
FIG. 60 is a side isometric, cross-sectional view of another
embodiment of the coaxial cable device.
FIG. 61 is a side isometric, cross-sectional view of one embodiment
of the coaxial cable device.
FIG. 62 is an exploded, isometric, cross-sectional view of one
embodiment of the coaxial cable device.
FIG. 63 is an isometric view of one embodiment of the inner
conductor and inner conductor engager illustrated in an initial
form.
FIG. 64 is an isometric view of one embodiment of the inner
conductor and inner conductor engager illustrated in a second or
final form.
FIG. 65 is a side isometric, cross-sectional view of one embodiment
of the coaxial cable device, illustrating one embodiment of the
crimping process and effect.
FIG. 66 is a side isometric view of one embodiment of the strain
relief device.
FIG. 67 is an isometric, cross-sectional view of the strain relief
device of FIG. 66.
FIG. 68 is a front view of the strain relief device of FIG. 66.
FIG. 69 is a back view of the strain relief device of FIG. 66.
FIG. 70 is a side view of the strain relief device of FIG. 66.
FIG. 71 is a side isometric view of another embodiment of the
strain relief device.
FIG. 72 is an isometric, cross-sectional view of the strain relief
device of FIG. 71.
FIG. 73 is a front view of the strain relief device of FIG. 71.
FIG. 74 is a back view of the strain relief device of FIG. 71.
FIG. 75 is a side view of the strain relief device of FIG. 71.
FIG. 76 is a perspective view of a coaxial cable having a helical
outer conductor which has been cut and stripped in preparation for
accepting a novel adaptor ring and weld washer useful for
fabricating a jumper cable according to one embodiment of the
description.
FIG. 77 is an exploded view of the adaptor ring including a ferrule
support ring and a ferrule cap for securing/capturing the weld
washer therebetween.
FIG. 78 is perspective view of the adaptor ring and weld washer
positioned over the cut/stripped end of the coaxial cable in
preparation for being penetration welded to the helical outer
conductor of the coaxial cable.
FIG. 79 is a front view of the prepared end of the coaxial cable
including the adaptor ring and the weld washer.
FIG. 80 is a sectional view along an elongate axis of the coaxial
cable to reveal the relevant internal components of the prepared
end of the jumper cable including the adaptor ring and the weld
washer.
FIG. 81 is an enlarged view of the weld washer prior to being
penetration welded to the helical outer conductor of the coaxial
cable.
FIG. 82 is perspective view of the adaptor ring and weld washer
positioned over the cut/stripped end of the coaxial cable
subsequent to being penetration welded to the helical outer
conductor of the coaxial cable.
FIG. 83 is a front view of the welded and assembled adaptor
ring/weld washer, i.e., subsequent to being penetration welded to
the helical outer conductor of the coaxial cable.
FIG. 84 is a sectional view along an elongate axis of the coaxial
cable to reveal the relevant internal components of the welded and
assembled adaptor ring/weld washer.
FIG. 85 is an enlarged view of the assembled adaptor ring/weld
washer subsequent to being deformed, welded and press fit onto the
coaxial cable.
FIG. 86 is a forward facing perspective view of the jumper cable
sectioned along the elongate axis to reveal the relevant details of
the weld washer, adaptor ring and coaxial cable connector.
FIG. 87 is a rearward facing perspective view of the jumper cable
sectioned along the elongate axis to reveal the relevant details of
the weld washer, adaptor ring and coaxial cable connector.
FIG. 88 is a view of the jumper cable sectioned along the elongate
axis to reveal the internal details of the weld washer, adaptor
ring and coaxial cable connector.
DETAILED DESCRIPTION
Part I
A detailed description of the hereinafter described embodiments of
the disclosed apparatus and method are presented herein by way of
exemplification and not limitation with reference to the Figures.
Although certain embodiments are shown and described in detail, it
should be understood that various changes and modifications may be
made without departing from the scope of the appended claims. The
scope of the present disclosure will in no way be limited to the
number of constituting components, the materials thereof, the
shapes thereof, the relative arrangement thereof, etc., and are
disclosed simply as an example of embodiments of the present
disclosure.
As a preface to the detailed description, it should be noted that,
as used in this specification and the appended claims, the singular
forms "a", "an" and "the" include plural referents, unless the
context clearly dictates otherwise.
Referring to the drawings, FIG. 1 depicts an embodiment of a
coaxial cable connector 100. Embodiments of connector 100 may be a
coaxial cable connector configured to operably attach to a coaxial
cable, such as a 50 Ohm coaxial cable. Connector 100 may be a
straight connector, a right angle connector, an angled connector,
an elbow connector, or any complimentary connector that may receive
a center conductor 18 of a coaxial cable 10. Further embodiments of
connector 100 may receive a center conductor 18 of a coaxial cable
10, wherein the coaxial cable 10 may include an annular corrugated,
spiral or helical corrugated, or smoothwall outer conductor 14. Two
connectors, such as connector 100, 300 may be utilized to create a
jumper that may be packaged and sold to a consumer. A jumper may be
a coaxial cable 10 having a connector, such as connector 100, 300,
operably affixed at one end of the cable 10 where the cable 10 has
been prepared, and another connector, such as connector 100, 300,
operably affixed at the other prepared end of the cable 10. For
example, embodiments of a jumper may include a first connector
including components/features described in association with
connector 100, 300, and a second connector that may also include
the components/features as described in association with connector
100, wherein the first connector is operably affixed to a first end
of a coaxial cable 10, and the second connector is operably affixed
to a second end of the coaxial cable 10. Embodiments of a jumper
may include other components, such as one or more signal boosters,
molded repeaters, and the like.
Referring to FIGS. 2A-2C, embodiments of a coaxial cable 10 may be
securely attached to a coaxial cable connector, such as through a
welded engagement. The coaxial cable 10 may include a center
conductor 18, such as a strand of conductive metallic material,
surrounded by an interior dielectric 16; the interior dielectric 16
may possibly be surrounded by an outer conductor 14; the outer
conductor 14 is surrounded by a protective outer jacket 12, wherein
the protective outer jacket 12 has dielectric properties and serves
as an insulator. Embodiments of the center conductor 18, or inner
conductor 18, may include a milled end 19. The milled end 19 of the
center conductor 18 may include a shoulder 17, such as an annular
lip configured to engage a surface of an electrical component of a
coaxial cable connector, such as electrical contact 70. Embodiments
of the center conductor 18 may have exposed aluminum in addition to
a copper clad external surface, or be made from aluminum with a
copper top surface. In other words, embodiments of the center
conductor 18 may be prepared in a manner such that the center
conductor 18 includes a concentric protrusion, or substantially
generally concentric protrusion for centering the center conductor
18 with the electrical contact 70. The outer conductor 14 may
extend a grounding path providing an electromagnetic shield about
the center conductor 18 of the coaxial cable 10. The outer
conductor 14 may be a semi-rigid or rigid outer conductor of the
coaxial cable 10 formed of conductive metallic material, such as
aluminum or copper, and may be smooth, corrugated or otherwise
grooved. For instance, the outer conductor 14 may be annularly
ribbed, as shown in FIG. 2A, smooth walled, as shown in FIG. 2B, or
spiral or helical corrugated, as shown in FIG. 2C. The coaxial
cable 10 may be prepared by removing a portion of the protective
outer jacket 12 so that a length of the outer conductor 14 may be
exposed, and then coring out a portion of the dielectric 16 to
create a cavity 15 or space between the outer conductor 14 and
jacket 12, and the center conductor 18. For instance, the cable 10
may be prepared in a manner that the jacket 12 and the dielectric
16 inside the cable 10 are removed by 1.5 corrugations
respectively, such that the outer conductor 14 extends
approximately 10-15 mm from beyond the dielectric 16 and jacket 12.
In some embodiments, the dielectric 16 is not removed or cored out
and extends approximately as far as the outer conductor 14.
Moreover, embodiments of the protective outer jacket 12 can
physically protect the various components of the coaxial cable 10
from damage that may result from exposure to dirt or moisture, and
from corrosion. Moreover, the protective outer jacket 12 may serve
in some measure to secure the various components of the coaxial
cable 10 in a contained cable design that protects the cable 10
from damage related to movement during installation in the field.
The outer conductor 14 can be comprised of conductive materials
suitable for carrying electromagnetic signals and/or providing an
electrical ground connection or electrical path connection. Various
embodiments of the outer conductor layer 14 may be employed to
screen unwanted noise. The dielectric 16 may be comprised of
materials suitable for electrical insulation. The protective outer
jacket 12 may also be comprised of materials suitable for
electrical insulation. It should be noted that the various
materials of which all the various components of the coaxial cable
10 should have some degree of elasticity allowing the cable 10 to
flex or bend in accordance with traditional broadband
communications standards, installation methods and/or equipment. It
should further be recognized that the radial thickness of the
coaxial cable 10, protective outer jacket 12, outer conductor 14,
interior dielectric 16, and/or center conductor 18 may vary based
upon generally recognized parameters corresponding to broadband
communication standards and/or equipment.
Referring back to FIG. 1, embodiments of connector 100 may include
a coupling interface 30, a sealing member 90, an electrical contact
70, a connector body 20, a first insulator body 50, and a second
insulator body 60.
Embodiments of connector 100 may include a coupling interface 30.
Embodiments of coupling interface 30 may include a first end 31, a
second end 32, an inner surface 33, and an outer surface 34.
Embodiments of the coupling interface 30 may be operably attached
to the connector body 20, wherein the coupling interface 30 may be
rotatable about the connector body 20. Furthermore, embodiments of
the coupling interface 30 may include an internal lip 37. The
internal lip 37 may engage a portion of the connector body 20, such
as a lip or annular edge, which can hinder or prevent axial
movement of the coupling interface 30 with respect to the connector
body 20. Embodiments of the coupling interface 30 may be configured
to physically mate or threadably engage a port, such an equipment
port on a cell tower or other broadband equipment, or another
coaxial cable connector. The coupling interface 30 may include a
threaded inner surface 33 proximate or otherwise near the second
end 32. Embodiments of the coupling interface 30 may be a nut, a
coupler member, a coupling, and the like. The coupling interface 30
may be comprised of conductive material, such as aluminum, brass,
copper, or any suitable metal. However, embodiments of the coupling
interface 30 may be comprised of both conductive materials and
insulator materials. Manufacture of the coupling interface 30 may
include casting, extruding, cutting, turning, tapping, drilling,
injection molding, blow molding, or other fabrication methods that
may provide efficient production of the component. Those in the art
should appreciate that various embodiments of the coupling
interface 30 may also comprise various inner or outer surface
features, such as annular grooves, detents, tapers, recesses, and
the like, and may include one or more structural components having
insulating properties located within the coupling interface 30.
Referring still to FIG. 1, embodiments of connector 100 may include
a sealing member 90 disposed onto the connector 100. Embodiments of
the sealing member 90 may sealingly engage portions of the cable 10
and connector body 20 while operably assembled to provide an
environmental seal for the connector 100 and/or to provide strain
relief. Embodiments of the sealing member 90 may be a seal, a
cover, a mould, a boot, a sealing boot, a strain relief member, and
the like. Embodiments of the sealing member 90 may be overmolded
over the connector 100. The sealing member 90 may be assembled onto
the connector 100 after the center conductor 18 and the outer
conductor 14 have been welded to the electrical contact 70 and the
outer housing 20, respectively. For instance, the sealing member 90
may be placed onto the cable 10 a distance away from the exposed
outer conductor 14 during the installation of the connector 100,
and then the sealing member 90 may be slid towards the coupling
interface 30 to cover the cable 10 and the connector 100 at a
desired location (e.g. Where the welds are located or to the rear
of the first end 31 of the coupling interface 30). The sealing
member 90 may provide a seal for the connector interface region to
prevent the ingress of moisture and/or other environmental elements
which may degrade or otherwise harm/damage the cable connection
(e.g. Welded connection) with the connector 100. The sealing member
90 may also provide strain relief. Moreover, the sealing member 90
may have a generally tubular body that is elastically deformable by
nature of its material characteristics and design. In most
embodiments, the sealing member 90 may be a one-piece element made
of a compression molded, elastomer material having suitable
chemical resistance and material stability (i.e., elasticity) over
a temperature range between about -40.degree. C. To +40.degree. C.
For example, the sealing member 90 may be made of silicone rubber.
Alternatively, the material may be propylene, a typical O-ring
material. The thickness and length of the sealing member 90 may
vary according to the desired elasticity and sealing properties
needed.
Referring to FIG. 1, and with additional reference to FIG. 3,
embodiments of connector 100 may include an electrical contact 70.
Embodiments of electrical contact 70 may include a first end 71, a
second end 72, and an exterior surface 74. Electrical contact 70
may be a conductive element that may extend or carry an electrical
current and/or signal from a first point to a second point. Contact
70 may be a terminal, a pin, a conductor, an electrical contact, a
curved contact, a bended contact, an angled contact, and the like,
and may be configured to be inserted into a conductive receptacle
or socket of a corresponding port or connector. Embodiments of the
electrical contact 70 should be formed of conductive materials.
Moreover, embodiments of electrical contact 70 may include a
receptacle 75 proximate or otherwise near the first end 71. The
receptacle 75 may be an opening, cavity, socket, receptacle
portion, inlet, and the like, that may receive the center conductor
18, in particular, the milled end 19 of the center conductor 18.
Embodiments of the receptacle 75 of the electrical contact 70 may
taper to a reduced diameter to match the shape/formation of the
milled end 19 of the center conductor 18; the receptacle 75 may
include a cross-section other than a taper, and may have a
cross-section that corresponds to the cross-section of the milled
end 19 of the center conductor 18. Additionally, embodiments of the
electrical contact 70 may include an annular protrusion 76 defining
an edge that may abut or engage a portion 56 of the first insulator
50.
Furthermore, embodiments of the electrical contact 70 may include a
face 78 proximate the first end 71 of the electrical contact 70.
Embodiments of the face 78 may be configured to engage the shoulder
17 of the center conductor 18. Embodiments of face 78 of the
electrical contact 70 may be a surface of the electrical contact 70
that is generally perpendicular to a central, longitudinal axis 5
of the connector 100. However, face 78 can be ramped or otherwise
non-perpendicular to the central axis 5. The face 78 of the
electrical contact 70 may also be defined as a mating edge or
surface of the electrical contact 70 that is configured to
physically engage the shoulder 17 of the milled end 19 of the
center conductor 18 in a final position of the connector 100. For
instance, the receptacle 75 may accept/receive the milled end 19 of
the incoming center conductor 18 of the coaxial cable 10 as coaxial
cable 10 is further inserted into the connector body 20, wherein
the milled end 19 of the center conductor 18 may be advanced into
the receptacle 75 of the electrical contact 70; those having skill
in the art should understand that the electrical contact 70 may be
advanced onto the milled end 19 of the center conductor 18.
Moreover, the electrical contact 70 may be welded to the center
conductor 18 at a first weld 120, as shown in FIG. 7. Embodiments
of the first weld 120 may be a weld or weld joint at a location
along the exterior surface 74 of the electrical contact 70 and the
exterior surface 18a of the center conductor 18a, where the
shoulder 17 of the center conductor 18 mates, contacts, or resides
proximate the face 78 of the electrical contact 70. Embodiments of
the first weld joint 120 may be along an outer surface 18a of the
center conductor 18, wherein the outer surface 18a is parallel or
substantially or approximately parallel to the central axis 5. The
first weld 120 may mechanically and electrically join the
electrical contact 70 and the center conductor 18 through a welding
process, thereby establishing a continuous electrical path between
the center conductor 18 and the electrical contact 70. The first
weld 120 may be annular, such that the weld encircles or extends
completely around the circumference of the center conductor 18;
however, in some examples, the first weld 120 may not extend
completely annularly around the circumference of the center
conductor 18 while still providing a continuous electrical path for
a central signal from the center conductor 18 through the
electrical contact 70. The first weld 120 may be created by laser
beam welding having either a continuous or pulsed laser beam. Those
having skill in the art should appreciate that although embodiments
of the first weld 120 is described as being created through a laser
welding process, other welding processes and techniques may be used
to weld, coalesce, or join two metal cable and connector
components, and other energy sources may be used, such as gas, gas
flame, electron beam, friction, ultrasound, and the like.
With continued reference to FIG. 1, and with additional reference
to FIG. 4, embodiments of connector 100 may include a connector
body 20. Embodiments of the connector body 20 may include a first
end 21, a second end 22, an inner surface 23, and an outer surface
24. Proximate or otherwise near the first end 21, the connector
body 20 may include a connector body ferrule portion 25, wherein
the connector body ferrule portion 25 may be surrounded by an
opening or radial cavity 26. Embodiments of the connector body
ferrule portion 25 may be structurally integral with the connector
body 20, and may have an inner diameter that is less than an inner
diameter of the connector body 20 proximate the second end 22. The
connector body ferrule portion 25 may be generally annular, and may
include a welding surface 28. Embodiments of the welding surface 28
of the connector body ferrule portion 25 may be an outer surface of
the connector body ferrule portion 25 that is configured to
weldingly engage the outer conductor 14 at a second weld 150, as
shown in FIG. 7. Embodiments of the welding surface 28 may be
parallel or substantially or approximately parallel to the central
axis 5. The connector body ferrule portion 25 may be disposed
within the cavity 15 of the cable 10, wherein the cavity 15 may be
defined as a radial space between an inner surface of the outer
conductor 14 and the outer surface of the center conductor 18 where
a portion of dielectric 16 has been removed. Embodiments of the
connector body ferrule portion 25 may be disposed within the cavity
15 of the cable until it makes contact with the dielectric 16
within the cable 10.
The outer diameter of the connector body ferrule portion 25 may be
sized and dimensioned to fit within/underneath the outer conductor
14, such that when the connector body 20 is attached or placed into
a position for attachment to the cable 10, the connector body
ferrule portion 25 physically contacts, or resides proximate, the
inner surface of the outer conductor 14. Embodiments of the second
weld 150 may be a weld or weld joint at a location where the outer
conductor 14 physically contacts the welding surface 28 of the
connector body ferrule portion 25. In one embodiment, the second
weld 150 may occur approximately 8 mm-17 mm from a forward, exposed
end of the outer conductor 14. Furthermore, embodiments of the
second weld 150 may occur at a valley of a corrugation of the outer
conductor 14 (if the outer conductor 14 is corrugated or otherwise
grooved). The second weld 150 may mechanically and electrically
join the connector body 20 and the outer conductor 14 through a
welding process, thereby establishing a continuous electrical path
between the outer conductor 14 and the connector body 20. The
second weld 150 may be annular, such that the weld encircles or
extends completely around the circumference of the outer conductor
14; however, in some examples, the second weld 150 may not extend
completely annularly around the circumference of the outer
conductor 14 while still providing a continuous electrical ground
path from the outer conductor 14 through the connector body 20. The
second weld 150 may be created by laser beam welding having either
a continuous or pulsed laser beam. Those having skill in the art
should appreciate that although embodiments of the second weld 150
is described as being created through a laser welding process,
other welding processes and techniques may be used to weld,
coalesce, or join two metal cable and connector components, and
other energy sources may be used, such as gas, gas flame, electron
beam, friction, ultrasound, and the like.
Embodiments of the connector body 20 may be a generally annular
member having a generally axial opening therethrough. An annular
lip 27 may define a change in an inner diameter of the connector
body 20; the lip 27 may define an increase in the inner diameter of
the connector body 20 with respect to the connector body ferrule
portion 25. Embodiments of a first insulator body 50 and a second
insulator body 60 may be configured to be disposed within the
general opening of the connector body 20, and may engage the
annular lip 27 to hinder further axial movement of the first and
second insulator bodies 50, 60 in a direction towards the cable 10.
Moreover, embodiments of the connector body 20 may include an
annular protrusion 24 that may include one or more edges configured
to cooperate with a lip, surface, or edge of the coupler interface
30. Embodiments of the connector body 20 may be comprised of
conductive material, such as aluminum, brass, copper, or any
suitable metal. However, embodiments of the connector body 20 may
be comprised of both conductive materials and insulator materials.
Manufacture of the connector body 20 may include casting,
extruding, cutting, turning, tapping, drilling, injection molding,
blow molding, or other fabrication methods that may provide
efficient production of the component. Those in the art should
appreciate that various embodiments of the connector body 20 may
also comprise various inner or outer surface features, such as
annular grooves, detents, tapers, recesses, and the like.
Referring still to FIG. 1, and with additional reference to FIG. 5,
embodiments of connector 100 may include a first insulator body 50.
Embodiments of the first insulator body 50 may include a first end
51, a second end 52, a disk portion 57 and ferrule portion 56.
Embodiments of the first insulator body 50 may be an insulator, an
insulating disk, a bead, and the like. Embodiments of the first
insulator 50 may be disposed within the connector body 20. For
instance, embodiment of the first insulator body 50 may be
inserted, snapped into, or press-fit within the general axial
opening of the connector body 20 and around the electrical contact
70, entering from the second end 22 of the connector body 20. The
first end 51 of the first insulator body 50 may contact the annular
lip 27 of the connector body 20, in particular, the disk portion 57
may be configured to physically contact or reside proximate the
annular lip 27 of the connector body 20, and may also peripherally
contact the inner surface of the connector body 20. Embodiments of
the disk portion of the first insulator body 50 may be slotted. For
example, the disk portion may include one or more openings 55.
Embodiments of the openings 55 may be slots, holes, openings,
tunnels, bores and the like. Moreover, embodiments of the first
insulator body 50 may include a ferrule portion 56 that is
structurally integral with the disk portion 57, so as have a "L"
shaped cross-section. Embodiments of the disk portion 57 and the
ferrule portion 56 may be configured to surround the electrical
contact 70 to electrically isolate and/or seal the electrical
contact, or central signal, from the connector body 20, or the
electrical ground path. Furthermore embodiments of the first
insulator body 50 may be made of non-conductive, insulator
materials, such as a plastic. Manufacture of the first insulator
body 50 may include casting, extruding, cutting, turning, drilling,
compression molding, injection molding, spraying, or other
fabrication methods that may provide efficient production of the
component.
Referring again to FIG. 1, with additional reference to FIG. 6,
embodiments of connector 100 may include a second insulator body
60. Embodiments of the second insulator body 60 may include a first
end 61, a second end 62, a mating surface 69, and an annular
recessed portion 69 proximate the second end 62. The second
insulator body 60 may be configured to surround the ferrule portion
56, or a portion of the ferrule portion 56 of the first insulator
body 50. For instance, embodiments of the second insulator body 60
may be disposed within the connector body 20, and around at least a
portion of the first insulator body 50. In some embodiments, when
the second insulator 60 is inserted within the connector body 20
and into engagement with the first insulator body 50, the
non-slotted second insulator body 60 may stabilize the slotted disk
portion 57 of the first insulator body 50 so that the center
conductor 18 can also be stabilized within the connector 100 in an
axial direction. Furthermore, embodiments of the second insulator
body 60 may also provide an electrical seal between the electrical
contact 70, or central signal, from the connector body 20, or the
electrical ground path.
With continued reference to the drawings, the manner in which the
connector 100 is assembled and/or installed will now be described.
FIG. 7 depicts an embodiment of connector 100 in an assembled,
welded position. The connector 100 is securably affixed to the
cable 10 through one or more welds, such as the first weld 120 and
the second weld 150. To arrive at the assembled, welded position,
an installer can attach the connector 100 to the cable 10. For
example, an installer may first prepare the cable 10 in a manner
that the jacket 12 and the dielectric 16 inside the cable 10 are
removed by approximately 1.5 corrugations of the outer conductor
14, which can range between 10 mm-17 mm in length from the end of
the outer conductor 14. In some embodiments, the number of
corrugations may be larger, and in the case of a smoothwall outer
conductor, the length of removed portion of jacket 12 and
dielectric may also be between approximately 10 mm-17 mm. Once the
jacket 12 is removed and the dielectric 16 is cored out to create
cavity 15, the electrical contact 70 (i.e. The inner conductor of
the connector) may be attached to the center conductor 18 by
placing the receptacle 75 of the electrical contact 70 over the
milled end 19 of the center conductor 18 until the face 78 of the
electrical contact makes contact or resides proximate the shoulder
17 of the center conductor 18. While the electrical contact is in
place, an installer may weld the center conductor 18 to the
electrical contact 70, using a laser or other energy source
and/technique, to create a first weld 120. The first weld 120 can
be along an exterior or outer surface 18a of the center conductor
18 and along an exterior or outer surface 74 of the electrical
contact 70, at a point or axial location where the two components
meet, as shown in FIGS. 8A and 8B. In embodiments where the
material of the center conductor 18 is copper or copper plated
brass, the first weld joint 120 may be performed between the copper
clad of the center conductor 18 and the electrical contact 70 of
the connector 100. In embodiments where the material of the center
conductor 18 is aluminum, the first weld joint 120 may be performed
between the core of the center conductor 18 and the electrical
contact 70.
After the electrical contact 70 of the connector 100 is welded to
the center conductor 18, the connector body 20 (and potentially the
coupling interface 30 rotatably attached to the connector body 20)
may be securably attached to the outer conductor 14 through a
second weld 150. An installer may place the connector body ferrule
portion 25 of the connector body 20 within the outer conductor 14
to a position where the outer conductor 14 can be welded to the
connector body ferrule portion 25. For instance, the connector body
ferrule portion 25 may be disposed within the outer conductor 14 of
the cable a distance such that the welding surface 28 of the
connector body ferrule portion 25 contacts the outer conductor 14
at one or more axial locations along the welding surface 28. In
other words, at least a portion of the connector body 20 may be
underneath at least one corrugation valley of an outer conductor
14. While the connector body 20 is in position within the outer
conductor 14 as described above, an installer may weld the outer
conductor 14 to the connector body 20, using a laser or other
energy source and/technique, to create a second weld 150, as shown
in FIG. 7 and FIG. 9. The second weld joint 150 can be created by
applying a laser beam to the outer conductor 14 (or connector body
ferrule portion 25) and using a melting material of the outer
conductor 14 of the cable 10 (or connector body ferrule portion 25)
as a filler material to weld the outer conductor 14 to the
connector body 20, or a particular embodiment, the connector body
ferrule portion 25 of the connector body 20.
Furthermore, after one or both the first weld 120 and second weld
150 have been created so as to weldingly secure the center
conductor 18 and the outer conductor 14 to the connector 100, a
sealing member, such as sealing member 90, may be advanced along
the cable 10 or connector 100 to cover any exposed portion of the
connector 100 or cable 10. For example, embodiments of the seal
member 90 may be rolled or otherwise advanced away from the
prepared end of the cable 10 to expose a portion of the outer
conductor 14 to allow access of the laser beam to weld the outer
conductor 14 to the connector body 20, and then the sealing member
90 may be rolled or otherwise advanced over the exposed outer
conductor 14 to seal, cover, protect, shelter, etc. The outer
conductor 14 and the second weld 150. Embodiments of the sealing
member 90 may also seal, cover, protect, etc. Portions of the cable
jacket 12, portions of the outer conductor 14, and portions of the
connector 100, such as the connector body 20. Additionally, an
installer may insert the first insulator body 50 and the second
insulator body 60 within the connector body 20, as described
above.
Referring still to the drawings, FIG. 10 depicts an embodiment of
connector 300. Embodiments of connector 300 may be a coaxial cable
connector configured to operably attach to a coaxial cable, such as
a 50 Ohm coaxial cable. Connector 300 may be a straight connector,
a right angle connector, an angled connector, an elbow connector,
or any complimentary connector that may receive a center conductor
318 of a coaxial cable 310. Further embodiments of connector 300
may receive a center conductor 318 of a coaxial cable 310, wherein
the coaxial cable 310 may include an annular corrugated, spiral or
helical corrugated, or smoothwall outer conductor 314. Embodiments
of cable 310, as shown in FIG. 11, may share the same or
substantially the same structural and/or functional aspects of
cable 10. However, embodiments of cable 310 may include a
dielectric layer 316 that is not cored out to create a cavity, such
as cavity 15. Those skilled in the art should appreciate that a
portion of the dielectric 316 may be cored out to create a cavity
or radial opening between the outer conductor 314 and the center
conductor 318 in some embodiments.
Embodiments of connector 300 may share the same or substantially
the same structural and functional aspects of connector 100. For
instance, embodiments of connector 300 may include a coupling
interface 330, a connector body 320, one or more insulator bodies
350, 355, 360, and a sealing member 390. However, embodiments of
connector 300 may include a welding component 340 to facilitate the
welding of the outer conductor 14 to the connector 300.
Embodiments of connector 300 may include a coupling interface 300;
embodiments of coupling interface 330 may share the same or
substantially the same structural and/or functional aspects as
coupling interface 390. Embodiments of coupling interface 330 may
include a first end 331, a second end 332, an inner surface 333,
and an outer surface 334. Embodiments of the coupling interface 330
may be operably attached to the connector body 320, wherein the
coupling interface 330 may be rotatable about the connector body
320. Furthermore, embodiments of the coupling interface 330 may
include an internal lip 337. The internal lip 337 may engage a
portion of the connector body 320, such as a lip or annular edge,
which can hinder or prevent axial movement of the coupling
interface 330 with respect to the connector body 320. Embodiments
of the coupling interface 330 may be configured to physically mate
or threadably engage a port, such an equipment port on a cell tower
or other broadband equipment, or another coaxial cable connector.
The coupling interface 330 may include a threaded inner surface 333
proximate or otherwise near the second end 332. Embodiments of the
coupling interface 330 may be a nut, a coupler member, a coupling,
and the like. The coupling interface 330 may be comprised of
conductive material, such as aluminum, brass, copper, or any
suitable metal. However, embodiments of the coupling interface 330
may be comprised of both conductive materials and insulator
materials. Manufacture of the coupling interface 330 may include
casting, extruding, cutting, turning, tapping, drilling, injection
molding, blow molding, or other fabrication methods that may
provide efficient production of the component. Those in the art
should appreciate that various embodiments of the coupling
interface 330 may also comprise various inner or outer surface
features, such as annular grooves, detents, tapers, recesses, and
the like, and may include one or more structural components having
insulating properties located within the coupling interface
330.
Referring still to FIG. 10, embodiments of connector 300 may
include a sealing member 390 disposed onto the connector 300;
embodiments of the sealing member 390 may share the same or
substantially the same structural and/or functional aspects of
sealing member 90. Embodiments of the sealing member 390 may
sealingly engage portions of the cable 10 and connector body 320
while operably assembled to provide an environmental seal for the
connector 300 and/or to provide strain relief. Embodiments of the
sealing member 390 may be a seal, a cover, a mould, a boot, a
sealing boot, a strain relief member, and the like. Embodiments of
the sealing member 390 may be overmolded over the connector 300.
The sealing member 390 may be assembled onto the connector 300
after the center conductor 318 and the outer conductor 314 have
been welded to the electrical contact 370 and the welding component
340, respectively. For instance, the sealing member 390 may be
placed onto the cable 310 a distance away from the exposed outer
conductor 314 during the installation of the connector 300, and
then the sealing member 390 may be slid towards the coupling
interface 330 to cover a portion of the cable 310 and the connector
300 at a desired location (e.g. Where the welds are located or to
the rear of the first end 331 of the coupling interface 330). The
sealing member 390 may provide a seal for the connector interface
region to prevent the ingress of moisture and/or other
environmental elements which may degrade or otherwise harm/damage
the cable connection (e.g. Welded connection) with the connector
300. The sealing member 390 may also provide strain relief.
Moreover, the sealing member 390 may have a generally tubular body
that is elastically deformable by nature of its material
characteristics and design. In most embodiments, the sealing member
390 may be a one-piece element made of a compression molded,
elastomer material having suitable chemical resistance and material
stability (i.e., elasticity) over a temperature range between about
-40.degree. C. To +40.degree. C. For example, the sealing member
390 may be made of silicone rubber. Alternatively, the material may
be propylene, a typical O-ring material. The thickness and length
of the sealing member 90 may vary according to the desired
elasticity and sealing properties needed.
With continued reference to FIG. 10, with additional reference to
FIG. 12, embodiments of the connector 300 may include a connector
body 320. Embodiments of connector body 320 may share the same or
substantially the same structural and/or functional aspects of
connector body 20, described in association with connector 100. For
instance, embodiments of connector body 320 may include a first end
321, a second end 322, an inner surface 323, an outer surface 324,
and a generally axial opening therethrough. However, instead of a
connector body ferrule portion, embodiments of connector body 320
may include an internal opening 328 or recess configured to receive
a welding component 340. Embodiments of the opening 328 may be
located proximate or otherwise near the first end 321 of the
connector body 320. Embodiments of the opening 328 may be defined
as a space, opening, void, recess, etc. Between an internal edge
329 and the first end 321 of the connector body 320. The size of
the opening 328 may depend on the axial distance from the first end
321 to the internal edge 329, as well as the internal diameter of
the connector body 320 from the first end 321 to the internal edge
329. The opening 328 may be sized and dimensioned to accommodate
the welding component 340. For instance, the welding component 340
may disposed within the connector body 320. In one embodiment, the
welding component 340 may be press-fit within the opening 328 of
the connector body 320. Moreover, embodiments of a first insulator
body 350 and a second insulator body 360 may be configured to be
disposed within the general opening of the connector body 320, and
may engage a portion of the welding component 340, cable 310,
and/or connector body 320 in an assembled position to hinder
further axial movement of the first and second insulator bodies
350, 360 in a direction towards the cable 310. Moreover,
embodiments of the connector body 320 may include an annular
protrusion 327 that may include one or more edges configured to
cooperate with a lip, surface, or edge of the coupler interface
330. Embodiments of the connector body 320 may be comprised of
conductive material, such as aluminum, brass, copper, or any
suitable metal. However, embodiments of the connector body 320 may
be comprised of both conductive materials and insulator materials.
Manufacture of the connector body 320 may include casting,
extruding, cutting, turning, tapping, drilling, injection molding,
blow molding, or other fabrication methods that may provide
efficient production of the component. Those in the art should
appreciate that various embodiments of the connector body 320 may
also comprise various inner or outer surface features, such as
annular grooves, detents, tapers, recesses, and the like.
Embodiments of the connector 300 may include an electrical contact
370; embodiments of electrical contact 370 may share the same or
substantially the same structural and functional aspects of
electrical contact 70. Embodiments of electrical contact 370 may
include a first end 371, a second end 372, and an exterior surface
374. Electrical contact 370 may be a conductive element that may
extend or carry an electrical current and/or signal from a first
point to a second point. Contact 370 may be a terminal, a pin, a
conductor, an electrical contact, a curved contact, a bended
contact, an angled contact, and the like, and may be configured to
be inserted into a conductive receptacle or socket of a
corresponding port or connector. Embodiments of the electrical
contact 370 should be formed of conductive materials. Moreover,
embodiments of electrical contact 370 may include a receptacle 375
proximate or otherwise near the first end 371. The receptacle 375
may be an opening, cavity, socket, receptacle portion, inlet, and
the like, that may receive the center conductor 318, in particular,
the milled end 319 of the center conductor 318. Embodiments of the
receptacle 375 of the electrical contact 370 may taper to a reduced
diameter to match the shape/formation of the milled end 319 of the
center conductor 318; the receptacle 375 may include a
cross-section other than a taper, and may have a cross-section that
corresponds to the cross-section of the milled end 319 of the
center conductor 318.
Furthermore, embodiments of the electrical contact 370 may include
a face 378 proximate the first end 371 of the electrical contact
370. Embodiments of the face 378 may be configured to engage the
shoulder 317 of the center conductor 318. Embodiments of face 378
of the electrical contact 370 may be a surface of the electrical
contact 370 that is generally perpendicular to a central axis 305
of the connector 300. However, face 378 can be ramped or otherwise
non-perpendicular to the central axis 305. The face 378 of the
electrical contact 370 may also be defined as a mating edge or
surface of the electrical contact 370 that is configured to
physically engage the shoulder 317 of the milled end 319 of the
center conductor 318 in a final position of the connector 300. For
instance, the receptacle 375 may accept/receive the milled end 319
of the incoming center conductor 318 of the coaxial cable 310 as
coaxial cable 310 is further inserted into the connector body 320,
wherein the milled end 319 of the center conductor 318 may be
advanced into the receptacle 375 of the electrical contact 370;
those having skill in the art should understand that the electrical
contact 370 may be advanced onto the milled end 319 of the center
conductor 318.
Moreover, the electrical contact 370 may be welded to the center
conductor 318 at a first weld 420, as shown in FIG. 13. Embodiments
of the first weld 420 may be a weld or weld joint at a location
along the exterior surface 374 of the electrical contact 370 and
the exterior surface 318a of the center conductor 318, where the
shoulder 317 of the center conductor 318 mates, contacts, or
resides proximate the face 378 of the electrical contact 370.
Embodiments of the first weld joint 420 may be along an outer
surface 318a of the center conductor 318, wherein the outer surface
318a is parallel or substantially or approximately parallel to the
central axis 305. The first weld 420 may mechanically and
electrically join the electrical contact 370 and the center
conductor 318 through a welding process, thereby establishing a
continuous electrical path between the center conductor 318 and the
electrical contact 370. The first weld 420 may be annular, such
that the weld encircles or extends completely around the
circumference of the center conductor 318; however, in some
examples, the first weld 420 may not extend completely annularly
around the circumference of the center conductor 318 while still
providing a continuous electrical path for a central signal from
the center conductor 318 through the electrical contact 370. The
first weld 420 may be created by laser beam welding having either a
continuous or pulsed laser beam. Those having skill in the art
should appreciate that although embodiments of the first weld 420
is described as being created through a laser welding process,
other welding processes and techniques may be used to weld,
coalesce, or join two metal cable and connector components, and
other energy sources may be used, such as gas, gas flame, electron
beam, friction, ultrasound, and the like.
Referring still to FIG. 10, and now with additional reference to
FIG. 14A, embodiments of connector 300 may include a welding
component 340. Embodiments of welding component 340 may be a
welding ring, a ring, an annular member, a collar, a sleeve, and
the like, or may be a metal component that can be welded to the
outer conductor 314 and be disposed within the connector body 320
to extend an electrical ground path through the connector 300. For
instance, the welding component 340 may be press-fit within the
opening 328 of the connector body 320, wherein the welding
component 340 makes physical and/or electrical contact with one or
more surfaces of the connector body 320. Embodiments of the welding
component 340 may be comprised of a single, unitary metallic
component, or may be comprised of more than one metallic component
capable of electrically conducting a ground path from the outer
conductor 314 to the connector body 320. Moreover, embodiments of
the welding component 340 may include a first end 341, a second end
342, an inner surface 343, an outer surface 344, and a generally
axial opening therethrough. The outer surface 344 of the welding
component 340 may be configured to engage, physically contact, etc.
The inner surface 323 of the connector body 320. Embodiments of the
welding component 340 may include a mating surface 345 at the
second end 242 configured to engage, physically contact, etc. The
internal edge 329 of the connector body 320. Additionally,
embodiments of the welding component 340 may include an annular
groove 347 somewhere along the outer surface 344. Embodiments of
the welding component 340 may be comprised of conductive material,
such as aluminum, brass, copper, or any suitable metal. However,
embodiments of the welding components 340 may be comprised of both
conductive materials and insulator materials. Manufacture of the
welding component 340 may include casting, extruding, cutting,
turning, tapping, drilling, injection molding, blow molding, or
other fabrication methods that may provide efficient production of
the component.
Furthermore, the welding component 340 may be welded to the outer
conductor 314 at a second weld 420. For instance, the internal
surface 343 may be configured to weldingly engage the outer
conductor 314 at a second weld 450, as shown in FIG. 14C.
Embodiments of the inner surface 343, or a welding surface of the
welding component 340, may be parallel or substantially or
approximately parallel to the central axis 305. Furthermore,
embodiments of the second weld 450 may occur at a peak of a
corrugation of the outer conductor 314 (if the outer conductor 314
is corrugated or otherwise grooved). The second weld 450 may
mechanically and electrically join the welding component 340 and
the outer conductor 314 through a welding process, thereby
establishing a continuous electrical path between the outer
conductor 314 and the welding component 340; the welding component
340 can be in physical and electrical contact with the connector
body 320 once the body 320 is installed onto the cable 310. The
second weld 450 may be annular, such that the weld encircles or
extends completely around the circumference of the outer conductor
314; however, in some examples, the second weld 450 may not extend
completely annularly around the circumference of the outer
conductor 314 while still providing a continuous electrical ground
path from the outer conductor 314 through the welding component 340
and through the connector body 320. The second weld 450 may be
created by laser beam welding having either a continuous or pulsed
laser beam. Those having skill in the art should appreciate that
although embodiments of the second weld 450 is described as being
created through a laser welding process, other welding processes
and techniques may be used to weld, coalesce, or join two metal
cable and connector components, and other energy sources may be
used, such as gas, gas flame, electron beam, friction, ultrasound,
and the like.
The connector body 320 may then be advanced over the welding
component 340 and the outer conductor 314 to operably attach to the
cable 310. For example, the connector body 320 may be advanced onto
the cable 310 until the first end 320 of the connector body 320
resides proximate the cable jacket 312. Embodiments of the
insulator bodies 350, 360 may also be disposed within the connector
body 320.
With continued reference to the drawings, the manner in which the
connector 300 is assembled and/or installed will now be described.
FIG. 10 depicts an embodiment of connector 300 in an assembled,
welded position. The connector 300 is securably affixed to the
cable 310 through one or more welds, such as the first weld 420 and
the second weld 450. To arrive at the assembled, welded position,
an installer can attach the connector 300 to the cable 310 after
the first and second weld joints 420, 450 have been created. For
example, an installer may first prepare the cable 310 in a manner
that the jacket 12 (and potentially the dielectric 316 inside the
cable 310) is removed by approximately 1.5 corrugations of the
outer conductor 314, which can range between 10 mm-17 mm in length
from the end of the outer conductor 314. In some embodiments, the
number of corrugations may be larger, and in the case of a
smoothwall outer conductor, the length of removed portion of jacket
312 may also be between approximately 10 mm-17 mm. Once the jacket
312 is removed, the electrical contact 370 (i.e. The inner
conductor of the connector) may be attached to the center conductor
318 by placing the receptacle 375 of the electrical contact 370
over the milled end 319 of the center conductor 318 until the face
378 of the electrical contact makes contact or resides proximate
the shoulder 317 of the center conductor 318. While the electrical
contact is in place, an installer may weld the center conductor 318
to the electrical contact 370, using a laser or other energy source
and/technique, to create a first weld 420. The first weld 420 can
be along an exterior or outer surface 318a of the center conductor
318 and along an exterior or outer surface 374 of the electrical
contact 370, at a point or axial location where the two components
meet, as shown in FIG. 13. In embodiments where the material of the
center conductor 318 is copper or copper plated brass, the first
weld joint 420 may be performed between the copper clad of the
center conductor 318 and the electrical contact 370 of the
connector 300. In embodiments where the material of the center
conductor 318 is aluminum, the first weld joint 420 may be
performed between the core of the center conductor 318 and the
electrical contact 370.
After the electrical contact 370 of the connector 300 is welded to
the center conductor 318, the welding component may be securably
attached to the outer conductor 314 through a second weld joint
450. Prior to attaching or placing the connector body 320 on the
cable 10, the welding component 340 may be laser welded onto the
outer conductor 314, as shown in FIGS. 14B and 14C. An installer
may then place, advance, attach the connector body 320 onto or over
the welding component 340 and the outer conductor 314. The second
weld joint 450 can be created by applying a laser beam to the outer
conductor 314 (or welding component 340), and using a melting
material of the outer conductor 314 of the cable 310 (or welding
component 340) as a filler material to weld the outer conductor 314
to the welding component 340.
Furthermore, after one or both the first weld 420 and second weld
450 have been created so as to weldingly secure the center
conductor 318 and the outer conductor 314 to the electrical contact
370 and the welding component 340, and the connector 300 has been
attached to the cable 310, a sealing member, such as sealing member
390, may be advanced along the cable 310 or connector 300 to cover
any exposed portion of the connector 300 or cable 310. For example,
embodiments of the seal member 390 may be rolled or otherwise
advanced away from the prepared end of the cable 310 to expose a
portion of the outer conductor 314 to allow the welding component
340 to be positioned over the outer conductor 314, and then the
sealing member 390 may be rolled or otherwise advanced over the
exposed outer conductor 314 to seal, cover, protect, shelter, etc.
The outer conductor 314 and the second weld 450. Embodiments of the
sealing member 390 may also seal, cover, protect, etc. Portions of
the cable jacket 312, portions of the outer conductor 314, and
portions of the connector 300, such as the connector body 320.
Additionally, an installer may insert the first insulator body 350
and the second insulator body 360 within the connector body 320, as
described above.
Referring still to the drawings. FIG. 15 depicts an embodiment of
connector 500. Embodiments of connector 500 may share the same or
substantially the same structural and/or functional aspects of
connector 300, as described above. For instance, embodiments of
connector 500 may weldingly engage a coaxial cable, such as cable
310, and may include a sealing member 590, an electrical component
570, a welding component 540, one or more insulator bodies 550,
560, and a connector body 550. Embodiments of connector 500 may
also be weldingly connected in a similar fashion as described in
association with connector 300. However, embodiments of connector
500 may include an extended connector body 550 configured to
accommodate a different union interface. Embodiments of connector
body 550 of connector 500 may also include an opening 528 to
accommodate the welding component 540 to extend a continuous
electrical ground path from the outer conductor 314 through the
connector 500. Those having skill in the art should appreciate that
various designs and versions of a connector body and/or coupling
interface may be used while still including one or more weld joints
as described herein.
With reference to FIGS. 1-15, an embodiment of a method of
attaching a coaxial cable connector to a coaxial cable may include
the steps of welding an electrical contact 70, 370 570 of the
coaxial cable connector 100, 300, 500 to a center conductor 18, 318
of the coaxial cable 10, 310 along an exterior surface 18a, 318a of
the center conductor 18, 318, disposing a portion of a connector
body 20, 320, 520 of the coaxial cable connector 100, 300, 500 into
a cavity 15 of the coaxial cable 10, 310 between an outer conductor
14, 314 and the center conductor 18, 318, and welding the portion
of the connector body 20, 320, 520 to the outer conductor 14, 314
of the coaxial cable 10, 310 along one or more axial locations on
the portion of the connector body 20, 320, 520. A further
embodiment of a method of attaching a coaxial cable connector 100,
300, 500 to a coaxial cable 10, 310 may include the steps of
welding an electrical contact 70, 370, 570 of the coaxial cable
connector 100, 300, 500 to a center conductor 18, 318 of the
coaxial cable 10, 310 along an exterior surface 18a, 318a of the
center conductor 18, 318, welding a welding component 340, 540 to
the outer conductor 314, and disposing the connector body 20, 320,
520 over the welding component 240 and the outer conductor 14,
314.
Part II
Referring to FIGS. 16-58, additional embodiments of coaxial cable
coaxial cable units, coaxial cable assemblies or coaxial cable
devices are illustrated. Depending upon the embodiment, the coaxial
cable device can include or exclude a segment of a coaxial cable.
In one embodiment illustrated in FIG. 16, the coaxial cable devices
700 can be mounted to, or installed in, different types of
electronic devices, including, but not limited to, a cellular
communication tower 702 or a cellular communication base station
703. Referring to FIG. 17, the coaxial cable device 700, in one
embodiment, includes a cable jumper having both of its ends
terminated by connectors 704.
In another embodiment illustrated in FIG. 18-23, the coaxial cable
unit or coaxial cable device 706 has: (a) a front or forward end
708 with a connector 704; and (b) a back or rearward end 710 which
is bare without a connector. The coaxial cable device 706, in one
embodiment, includes a coaxial cable 712 attached to the connector
704. The coaxial cable 712 includes: (a) an inner wire, central
conductor or inner conductor 714; (b) an insulating layer,
dielectric or insulator 716 which surrounds the inner conductor
714; (c) a tube or outer conductor 718 which surrounds the
insulator 716; and (d) a cover, sleeve or jacket 720 which
surrounds the outer conductor 718. In one embodiment illustrated in
FIGS. 54-58, the inner conductor 714 has a central region or core
722 including a material such as aluminum. The inner conductor 714
also has an outer region or outer layer 725 including a different,
more conductive material, such as copper. Depending upon the
embodiment, the outer conductor 718 may have a uniform or
non-uniform shape. In the embodiment shown, the outer conductor 718
has a wavy, ridged or corrugated shape defining a continuous series
of peaks and valleys.
With continued reference to FIGS. 18-23, the connector 704 of the
cable device 706, in one embodiment, includes: (a) a connector
structure, connector housing or connector body 724; (b) an outer
conductor receiver or outer conductor engager 726 which is
positioned within the rearward section 728 of the connector body
724; (c) a tubular plug or jacket seal 730 which receives the
jacket 720 and is partially nested between the jacket 720 and outer
conductor engager 726; (d) a compressor 732 housed within the
connector body 724; (e) an inner conductor engager 734 moveably or
slidably positioned within the compressor 732; (f) a compression
driver 733 configured to drive the inner conductor engager 734 into
the compressor 732; (g) a fastener or coupler 736 which is
rotatably coupled to the forward section 739 of the connector body
724; (h) a plurality of annular or ring-shaped fluid seals or
liquid seals 740 and 741; and (i) a rearward seal, strain relief
device, cover or boot 738 which receives, and covers, part of the
jacket 720, the jacket seal 730, and the rearward section 728 of
the connector body 724.
In one embodiment illustrated in FIGS. 41-44, the connector body
724 has a generally cylindrical, tubular or barrel shape, including
a body exterior wall 742 and a body interior wall 743. The body
exterior wall 742 has: (a) boot mating region 744, including a
circumferential notch 746 and defining a circumferential groove
748; (b) a coupler seal wall 750 defining a seal groove 752 shaped
to receive seal 740; (c) a circumferential coupler retaining wall
754 which moveably interfaces with the circumferential coupler lip
or coupler retaining wall 746 of the coupler 736; and (d) a collar
section 756 around which the seal 741 fits. The body interior wall
743 has: (a) a circumferential step 760 shaped to mate with the
circumferential step 762 of the outer conductor engager 726; and
(b) a circumferential compressor stop 764 configured to engage the
circumferential notch 766 of the compressor 732. The connector body
724, in one embodiment, is constructed of a conductive material,
such as a metal suitable for grounding purposes.
In one embodiment illustrated in FIGS. 28-31, the outer conductor
engager 726 has an exterior wall 768 and an interior wall 770. The
exterior wall 768 has: (a) the circumferential step 762 and valley
wall 766 configured to mate with the connector body 724 as
described above; and (b) a circumferential slot wall 769 defining a
groove shaped to receive an annular or ring-shaped seal, such as an
O-ring. The interior wall 770 has: (a) a circumferential seal stop
or seal engager 771 configured to engage the seal 730; and (b) an
outer conductor engagement wall 772 which contacts the outer
conductor 718. The outer conductor engager 726, in one embodiment,
is constructed of a conductive material, such as a metal suitable
for grounding purposes. When engaged with the outer conductor 718
and connector body 724, the outer conductor engager 726 is operable
to have an electrical grounding function.
Referring to FIGS. 45-46 and 50-53, in one embodiment, the outer
conductor engager 726 is welded to the outer conductor 718. In the
first manufacturing step, as illustrated in FIG. 45, a bare end of
the coaxial cable is prepared. This involves cutting away a portion
of the jacket 720, outer conductor 718, and insulator 716 as
illustrated. As a result, inner conductor 714 extends outward
furthest, and the edge 776 of the outer conductor 718 extends along
a cut peak 774, resulting in an outwardly flared-section 778. Also,
the face 780 of the insulator 716 is inset relative to the edge
776.
After the first manufacturing step, a suitable die or tool is used
to bend or fold the edge 776 inward toward the center conductor
714. In one embodiment, the edge 776 is folded back onto itself
until it contacts the interior surface 779 of the flared-section
778. The result, illustrated in FIG. 46, is a partially or fully
closed hem section 780. The hem section 780 is, in one embodiment,
an outer conductor weld zone, outer conductor weld area or outer
conductor weld interface 781.
As illustrated in FIGS. 50-51, the outer conductor engagement wall
772 has a slanted, angled or ramped section 782. The ramped section
782 is located adjacent to, and is engaged with, the hem section
780. The ramped section 782 is, in one embodiment, an outer
conductor engager weld zone, outer conductor engager weld area or
outer conductor engager weld interface 783.
As illustrated in FIGS. 50-53, a welding device 784 is operated to
direct focused energy toward the hem section 780. Consequently, the
hem section 780 is welded to, or with, the ramped section 782.
Depending upon the embodiment, one or both of the sections 780 and
782 can fully or partially liquefy and intermix during the welding
process. In one embodiment, the welding device 784 implements laser
beam welding to aim a laser beam at the hem section 780 and
gradually move the laser beam around the perimeter of the hem
section 780. It should be understood, however, that any suitable
type of welding device or energy director can be operated to: (a)
weld or fuse the sections 780 and 782 together; (b) weld or fuse
the hem section 780 to the ramped section 782; or (c) connect the
hem section 780 to the ramped section 782 by adding a metallic,
meltable filler or flux which functions to hold the sections 780
and 782 together. It should also be understood that any suitable
type of welding energy can be used, including, but not limited to,
laser, electric arc, electron beam, ultrasound and gas flame. After
cooling, the outer conductor engager 726 is weldably connected to
the outer conductor 718.
Referring to FIGS. 19-23 and 38-40, the compressor 732 includes an
exterior compressor wall 786, which has the circumferential notch
766 described above. The interior compressor wall 788 of the
compressor 732 has a compression chamber 790 and a throat section
792. The compression chamber 790 and throat section 792 are shaped
to mate with, and conform to the geometry of, the inner conductor
engager 734 as described below. In one embodiment, the compressor
732 is an insulator, constructed of polymer, functioning to
maintain an insulation barrier between the inner conductor engager
734 and the connector body 724. This barrier reduces the likelihood
of an electrical short caused by an undesired electrical connection
between the inner conductor 714 and the outer conductor 718.
Referring to FIGS. 19-25 and 32-34, the compression driver 733 is
generally disk-shaped and has: (a) a rearward driver face 794 which
is oriented toward the insulator face 780; (b) a forward driver
face 796 which is oriented toward the inner conductor engager 734;
and (c) a driver body 798 between the faces 794 and 796. The driver
body 798 has a central conical wall 800 defining a central opening
802.
The driver body 798 also defines an array of equidistant reflection
reduction slots 804. The reflection reduction slots 804 enable
electrical signals to pass through the connector 704. This reduces
the amount of signal reflection within the connector 704 which, in
turn, results in a suitable, or more desirable, return loss. In one
embodiment, the coaxial cable 712 has a designated impedance factor
which represents the opposition to signal flow within the coaxial
cable. The designated impedance factor depends on the internal
geometry, dimensions and material types of the cable. In one
embodiment, the connector 704 has an impedance factor which is the
same as, of substantially similar to, the designated impedance
factor of the cable 712. This impedance compatibility reduces
internal signal reflections at connections between components. The
reflection reduction slots 804 and other cavities and passageways
of the connector 704 assist in the reduction of such signal
reflection.
With continued reference to FIGS. 19-25 and 32-34, the opening 802
of the compression driver 733 is large enough to receive the inner
conductor 714 but, in the illustrated embodiment, opening 802 is
sized to block entry of the inner conductor engager 734. As
illustrated in FIGS. 33-34, the forward face 796 has a plurality of
equidistant notches or alignment guides 806. The alignment guides
806 facilitate the alignment of the compression driver 733 with the
inner conductor engager 734 as described below.
Referring to FIGS. 19-25 and 35-37, the inner conductor receiver or
inner conductor engager 734 includes a mouth section 808 and a neck
section 810. The mouth section 808 has a ramped or tapered shape,
and the mouth section 808 has a plurality of flexible grasps or
jaws 812. The exterior wall 814 of each jaw 812 extends along an
axis 815 which intersects with a horizontal or longitudinal axis
817, resulting in angle 819 at the vertex. It should be understood
that the jaws 812 extend along their respective axes 814 when the
inner conductor engager 734 is in its predisposed state. In this
predisposed state, the mouth section 808 defines a space or cavity
816 sized to receive the inner conductor 714.
As illustrated in FIG. 24, the cavity 818 is great enough to
provide a gap 820 between the inner conductor 714 and the jaws 812.
During installation, as illustrated in FIG. 24, the left assembly
822 is moved toward the right assembly 824. During the movement,
the guides 806 of the compression driver 733 align the inner
conductor engager 734 for engagement. Then the compression driver
733 pushes or drives the inner conductor engager 734 into the
compressor 732 until the mouth section 808 of the inner conductor
engager 734 fully seats within the compression chamber 790 of the
compressor 732. The full seating is reached when the bottom wall
826 of the mouth section 808 abuts the floor 828 of the compression
chamber 790, illustrated in FIG. 40.
Referring to FIG. 40, the compression chamber wall 830 extends
along a chamber wall axis 832. In the illustrated embodiment, the
chamber wall axis is parallel, or substantially parallel, with the
longitudinal axis 818. In another embodiment, the chamber wall axis
832 intersects with the longitudinal axis 818. In such embodiment,
the vertex angle of the intersecting axes 832 and 818 is less than
the vertex angle 819 of the intersecting axes 814 and 818. As a
result, when the mouth section 808 of the inner conductor engager
734 is driven into the compression chamber 790, the compression
chamber wall 830 applies a radial force onto the jaws 812. In
response, the jaws 812 press down upon, grasp and engage the inner
conductor 714, as illustrated in FIG. 25.
Referring to FIGS. 19 and 23, in one embodiment, the seals 740 and
741 includes O-rings of a suitable size and shape to reduce or
minimize the entry of fluid or liquid into the cable device 706.
When the coupler 736 is securely screwed onto a threaded post of
another component, the seal 741 forms a seal with the
component.
Referring to FIGS. 23 and 27, in one embodiment, the plug or seal
730 has a generally tubular shape and is constructed of a suitably
compressible or deformable material. The seal 730 includes: (a) an
outer conductor engager mating wall 731 configured to mate with the
seal engager 771 of the outer conductor engager 726; (b) a boot
mating wall 735 configured to mate with the seal mating wall 836 of
the strain relief device or boot 738; and (c) a cable engagement
wall 737 configured to compress and engage the cut end of the
jacket 720 and the exposed part of the outer conductor 718. The
seal 730 is operable to reduce the entry of fluids or liquid into
the cable 712 or connector 704.
Referring to FIGS. 23 and 26, in one embodiment, the strain relief
device, cover or boot 738 has: (a) a circumferential seal mating
wall 836 configured to mate with the rearward wall 838 of the seal
730; (b) a circumferential intermediate mating wall 840 configured
to mate with the rearward wall 842 of the outer conductor engager
726; and (c) a circumferential notch 842 configured to snap-fit
into groove 748 of the connector body 724. In one embodiment, the
strain relief device or boot 738 has a relatively rigid structure
formed of polyethylene or another suitable material. To install the
boot 738, the assembler slides the boot 738 over the connector body
724 until the notch 842 fits into the groove 748. At this point,
the coaxial cable device 706 is assembled.
In one embodiment, the fastener or coupler 736 has a plurality of
internal threads 846. The threads 846 enable one to screwably
connect the coaxial cable device 706 to a threaded post of a
connector of another coaxial cable, to the threaded post of an
electronic telecommunications device or to a threaded post of an
interface port.
In another embodiment illustrated in FIGS. 54-58, the inner
conductor engager is welded to the inner conductor 714 instead of
being compressed onto the inner conductor 714. In such embodiment,
the coaxial cable connector includes all of the components and
elements of coaxial cable connector 704 except that: (a) the
compression driver 733 is excluded; (b) the shape of the compressor
732 is modified as described below; and (c) the shape of the inner
conductor engager 734 is modified as described below.
Referring to FIG. 54, in one such embodiment, the inner conductor
engager 848 has a cup-shape including: (a) a side wall 850 having
an entry edge or rearward edge 852 configured to receive the inner
conductor 714; and (b) a closed end or floor 854. The side wall 850
has a plurality of spaced-apart, longitudinal slots 856. Each slot
856 is defined by a plurality of weldable edges 858. Each slot 856
extends along an axis 860 which is parallel with the longitudinal
axis 862 extending through the inner conductor engager 848.
The compressor 732, in this embodiment, is modified to become a
support or holder for the inner conductor engager 848. The exterior
of the holder is the same as that of compressor 732. The interior
of the mouth section 808, however, is modified to have a slightly
larger diameter than the diameter of the side wall 850. This
enables the modified mouth section to receive the side wall 850
without compressing the side wall 850.
After the outer conductor engager 726 is welded to the outer
conductor 718, as described above, the assembler inserts the inner
conductor 714 into the inner conductor engager 848. Next, using the
welding device 784, the assembler directs the welding energy at the
weldable edges 858 and the underlying and adjacent portions of the
inner conductor 714. After cooling, the inner conductor engager 848
is welded to, or with, the side wall 859 of the inner conductor
714. In the illustrated embodiment, the inner conductor engager 848
has three slots 856 which are equally spaced apart around the
circumference of the side wall 850. It should be appreciated,
however, that the inner conductor engager 848 can have any suitable
number of slots 856.
In one embodiment, the arrangement of the slots 856 (including the
quantity, size, shape and location of the slots 856) is associated
with a designated, weldable surface area of the inner conductor
714. The designated weldable surface area corresponds to a suitable
welding strength. The strength is achieved by full or partial
melting of the outer copper layer 725 without involving a liquid
intermixing between the copper layer 725 and aluminum core 722. In
one embodiment, the strength is achieved based on the melting of
the weldable edges 858 and the melting of the copper layer 725
without the inclusion of any liquefied aluminum from the aluminum
core 722.
In one embodiment, the outer layer 725 includes a suitable
composition of copper and one or more other types of metals or
non-metals. There is a suitable percentage of copper within the
layer 725 for a suitable level of conductivity. In such embodiment,
there is a ratio between (a) and (b), where (a) is the total welded
or weld-treated surface area on the side wall 859 of the inner
conductor, and (b) is the percentage of copper that remains within
the outer layer 725 after the welding process is complete. This
ratio falls within a range which is associated with the following
factors: (a) a suitable tensile strength within the weld connection
between the inner conductor 714 and the inner conductor engager
848; and (b) a suitable level and uniformity of conductivity for
the electrical performance of the coaxial connector assembly.
Referring to FIG. 55, in one such embodiment, the inner conductor
engager 872 is the same as inner conductor engager 848 except that
the slots 856 are replaced with the slots 874. Each slot 874 is
defined by a plurality of weldable edges 876.
Referring to FIG. 56, in one such embodiment, the inner conductor
engager 878 is the same as inner conductor engager 848 except that
the slots 856 are replaced with the array or grid pattern of
openings or holes 880. Each hole 880 is defined by a continuous,
weldable edge 882.
Referring to FIG. 57, in one such embodiment, the inner conductor
engager 884 is the same as inner conductor engager 848 except that
the slots 856 are replaced with a plurality of windows 886. Each
window 868 is defined and bound by a plurality of weldable edges
870 which form an opening through the window 868. Each window 868
extends along an axis 860 which is parallel with the longitudinal
axis 862 extending through the inner conductor engager 848.
Referring to FIG. 58, in one such embodiment, the inner conductor
engager 884 is the same as inner conductor 848 except that the
slots 856 are replaced with a single vertical window 888. The
single vertical window 888 is defined and bound by a plurality of
weldable edges 890 which form an opening through the window 888.
The vertical window 888 extends along a vertical axis 892 which is
non-parallel with the longitudinal axis 862.
In one embodiment, the coaxial cable connector is detached from the
coaxial cable 712, though the coaxial cable connector is configured
to be welded to the cable 712 as described above. In such
embodiment, an assembler can weld the coaxial cable connector to a
cable 712 inside a manufacturing facility or in the field. For
in-field installations, the welding device 784, in one embodiment,
includes a battery-powered, mobile welder. The mobile welder
includes a connector engagement device configured to hold the
coaxial cable connector and align the connector with the beam or
stream of welding energy.
Part III
Referring to FIGS. 59-60, in one embodiment the coaxial cable
device 1010 includes all of the components and functionality of
coaxial cable device 706 except that cable connector 704 is
replaced with cable connector 1012. Cable connector 1012 includes
all of the structure and components of connector 704 as illustrated
in FIG. 59 and described above. In addition, cable connector 1012
includes: (a) an outer conductor engager 1014 which receives,
engages and holds the outer conductor portion 1016, strain relief
device seal 1017, jacket seal 1018 and jacket portion 1020; (c) a
spacer 1022 which supports the outer conductor portion 1016 and
functions as a dielectric, safeguarding against a short circuit
between the inner conductor 714 and outer conductor 718; (d) an
inner conductor engager holder 1024 which holds the inner conductor
engager 1025, aligns the inner conductor engager 1025 with the
inner conductor 714 and also functions as a dielectric,
safeguarding against a short circuit between the inner conductor
714 and outer conductor 718; and (e) a cable stabilizer, cable
guide or strain relief device 1026 engaged with the jacket 720,
outer conductor engager 1014 and connector body 724.
In one embodiment illustrated in FIG. 60, the outer conductor
engager 1014 includes: (a) a jacket engagement portion 1028 which
engages and compresses the jacket portion 1020; (b) a strain relief
device seal holder 1030 having walls 1032 and 1034 which retain and
hold the strain relief device seal 1017; (c) a jacket seal holder
1036 configured to retain and hold the jacket seal 1018; and (d) a
weld interface portion 1038 which is welded to the outer conductor
portion 1016. By securing and engaging the jacket portion 1020
while being welded to the outer conductor portion 1016, the outer
conductor engager 1014 is operable to strengthen the connection of
the connector 1012 to the cable 712.
In this way, the outer conductor engager 1014 serves multiple
functions at the same time. One function is to mechanically secure
and couple the connector body 724 to the cable 712 by compressing
and engaging the jacket 720. Another function is to hold the seals
1017 and 1018 for inhibiting the entrance of liquid or fluid into
the connector 1012. Yet another function is to electrically ground
the outer conductor 718 by being welded to the outer conductor 718.
Still another function is to further the mechanical connection of
the connector 1012 to the cable 712 through the weld joint.
In one embodiment illustrated in FIGS. 61-62, the spacer 1022 has
the configuration of driver 733 except that spacer 1022 has an
outer conductor support 1040. The outer conductor support 104
includes a raised, circular wall which engages, abuts and supports
the outer conductor portion 1016. When the weld interface portion
1038 is welded to the outer conductor portion 1016, the outer
conductor support 1040 provides additional support to the weld
joint.
Referring to FIGS. 63-65, in one embodiment, an assembler
transforms inner conductor engager 1025 from the initial form 1042
illustrated in FIG. 63 to the final or deformed form 1044
illustrated in FIGS. 64-65. The assembler inserts the inner
conductor 714 into the cavity 1048 defined by the inner conductor
engager 1025. Next, the assembler uses a die or tool, such as
crimping tool 1046, to force a deformer against the outer,
cylindrical surface 1050. In the illustrated example, the deformer
has a flat, rectangular shape forming the rectangular, recessed
spaces, crimp zones or depressions 1052. After the depressions 1052
are formed, the inner conductor engager 1025 is mated with,
crimpled with, interlocked with or otherwise frictionally engaged
with the inner conductor 714.
In one embodiment illustrated in FIG. 65, the depression 1052
causes the inner conductor engager 1025 to have a plurality of
depression walls 1054 and 1056. Also, the depression 1052 causes
the inner conductor 714 to have a plurality of depression walls
1058 and 1060. In one embodiment, there is a frictional force and
mating between the walls 1054 and 1058. Also, there is a mating
between walls 1056 and 1060. The mating of the walls 1054 with 1058
and walls 1056 with 1060, secures the engagement of the inner
conductor engager 1025 with the deformed inner conductor 714.
During use of the coaxial cable device 1010, the engager 1025 and
conductor 714 can be pulled apart or subject to tensile loads,
where the pulling force acts along axis 1062. In such event, the
wall 1054 would interfere with wall 1058 establishing an interlock
to keep the engager 1025 and conductor 714 together. Depending upon
the embodiment, the walls 1054, 1058, 1056 and 1060 can be knurled
or otherwise configured to have surface ridges, grooves or bumps to
increase the frictional fit between the engager 1025 and conductor
714. Also, differently shaped crimping tools can be used to form
differently shaped depressions within the engager 1025 and
conductor 714. For example, the inner conductor 714 can have a
depression with a particular angled slot, and a tool can push the
engager 1025 into such depression, causing its metal to flow into
the angled slot, forming an interlock.
Referring to FIGS. 63 and 65, in one embodiment, the depression
1052 remains within the outer copper layer 725 without reaching the
aluminum core 722. As a result, the conduction occurs substantially
between the copper of the conductor 714 and the copper of the
engager 1042.
Referring to FIG. 61, in one embodiment, the outer conductor
engager 1014 is separated into: (a) a jacket-relief engager 1064
which receives, engages and holds the strain relief device seal
1017, jacket seal 1018 and jacket portion 1020; and (b) an outer
conductor engager 1066 which receives, engages, holds, and is
welded to the outer conductor portion 1016. The jacket-relief
engager 1064 mates with the outer conductor engager 1066, and when
compressed together, they function as a single unit. In this
embodiment, the outer conductor engager 1066 is formed of a copper
material for conducive purposes, and the jacket-relief engager 1064
is formed of a different, lower cost material, such as a suitable
metal or rigid plastic. One embodiment includes a set of different
outer conductor engagers 1066, where each such engager is
configured to engage a different type of outer conductor. For
example, outer conductor engager A can be formed of aluminum for
being welded to an aluminum outer conductor. In another example,
outer conductor engager B can have a particular shape for being
welded to a smooth-walled outer conductor. The interchangeability
of such outer conductor engagers can facilitate the use of the
connector 1012 with different types of cables 712.
Referring to FIG. 59, in one embodiment, the strain relief device
1026 has: (a) a body 1068 which engages and presses against the
jacket 720; (b) strain relief device walls 1070 which define a
space configured to receive part of the connector body 724; and (c)
a coupling wall 1072 which snap fits into a recess 1074 defined by
the connector body 724. In one embodiment, strain relief device
1026 is formed of a rigid or semi-rigid material. In another
embodiment, strain relief device 1026 is formed of an elastic or
resilient material. In operation, the strain relief device 1026
relieves stress on the cable 720 when the cable 720 is bent
relative to the axis 1062 illustrated in FIG. 65.
In another embodiment illustrated in FIGS. 60-61, the strain relief
device 1076 has the same elements and components as strain relief
device 1026 except that the strain relief device 1076 also has
spaced-apart, inner walls 1078 which define space 1080. In one
embodiment, the inner walls 1078 are partially elastic and
flexible. As such, the inner walls 1078 are operable to produce a
spring force onto the jacket 712 and connector body 724.
Referring to FIGS. 66-70, in one embodiment, the strain relief
device 1082 has the same components and function as strain relief
device 1026 except for the geometrical differences illustrated in
FIGS. 66-70. It should be appreciated that the strain relief device
1082 is symmetrical in a radial direction. Put another way, the
sides 1084, top 1086 and bottom 1088 of strain relief device 1082
are identical in geometry while the front end 1090 is different
from the back end 1092.
Referring to FIGS. 71-75, in one embodiment, the strain relief
device 1094 has the same components and function as strain relief
device 1026 except for the geometrical differences illustrated in
FIGS. 71-75. It should be appreciated that the strain relief device
1094 is symmetrical in a radial direction. Put another way, the
sides 1096, top 1098 and bottom 1100 of strain relief device 1094
are identical in geometry while the front end 1102 is different
from the back end 1104.
Part IV
The following section is directed to a jumper cable having a
"prepared end" suitable for receiving and mounting a coaxial cable
connector. The jumper cable is prefabricated to a prescribed
length, e.g., 6 ft, 10 ft, and/or 20 ft in length. Such jumper
cables are typically used when making connections between an
antenna and one or more Remote Radio Heads (RRH) on a base station
cell tower.
FIG. 76 depicts an perspective end view of a coaxial cable 2000
having: (i) an elongate inner conductor 2002, (ii) a helical outer
conductor 2004, (iii) a dielectric material 2006 disposed between
the inner and outer conductors 2002, 2004, and, (iv) a complaint
outer jacket 2010 disposed over the helical outer conductor 2004.
Commercially, the coaxial cable 2000 is known as a spiral, helical
or "superflex" coaxial cable 2000. The cable 2000 is strip/cut
along vertical planes VP1, VP2 such that the helical outer
conductor 2004 exposes an end portion 2012 of the inner conductor
2002 and the compliant outer jacket 2010 exposes an end portion
2014 of the outer conductor 2004. In the described embodiment, four
(4) helical ribs, or corrugations 2016, are shown extending beyond
the vertical plane VP2 corresponding to the end of the compliant
outer jacket 2010. The dielectric material 2006 may be cored from
between the inner and outer conductors 2002, 2004 depending upon
the density of the dielectric 2006. In the described embodiment,
the wall thickness of the helical outer conductor 2004 is between
about 0.025 inches to about 0.100 inches, and the lead angle
.alpha. of the helix is about ten degrees (10.degree.) relative to
the vertical plane VP1.
FIG. 77-80 depict exploded and assembled views of an adaptor ring,
or ring subassembly 2020 disposed in combination with a weld washer
2022. When assembled and secured a coaxial cable 2000, the adaptor
ring 2020 provides a prepared end operative to support and mount a
coaxial cable connector. In the described embodiment, the adaptor
ring 2020 envelops a portion of the weld washer 2022 and comprises
a ferrule support member 2024 on one side of the weld washer 2022
and a ferrule cap, or cap member, 2026 on the other side of the
weld washer 2022. The weld washer 2022 is split along a line RL
(see FIG. 77), and includes: (i) a central opening 2028, (ii) an
outer diameter D, and, (iii) an anti-rotation surface 2030 disposed
along the periphery of the outer diameter D. The central opening
2028 of the weld washer 2022 is coaxially aligned with openings
2032 and 2034, disposed in each of the ferrule support and cap
members 2024 and 2026, respectively, for the purpose of receiving
the inner and outer conductors 2002, 2004 of the coaxial cable 2000
(see FIG. 78). While the openings 2028, 2032 and 2034 facilitate
the passage of the conductors 2002, 2004, it should be appreciated
that the openings 2032, 2034 are also configured to secure an outer
peripheral edge 2004E of the weld washer 2022, i.e., retaining the
weld washer 2022 axially and rotationally between the ferrule
support and cap members 2024, 2026.
In the described embodiment, the thickness t of the weld washer
2022 is about two (2.times.) to four (4.times.) times the wall
thickness of the helical outer conductor 2004. Furthermore, the
weld washer 2022 is severed, cut or split along the line RL, and
stamped such that the edges of the severed washer are out-of-plane,
i.e., relative to a plane VP3 orthogonal to an elongate axis 2020A
of the ring subassembly 2020. While the weld washer 2022 is shown
to be split or cut along a chord line, it will be appreciated that
the weld washer may be severed along radial or tangential line.
Furthermore, while the weld washer 2022 is fully split to
facilitate threaded engagement, it will be appreciated that the
weld washer 2022 may be partially split or severed. A portion of
the weld washer 2022, therefore, will be severed and another
portion will be integral, forming a continuous washer ring.
Finally, the weld washer 2022 is fabricated from an oxygen-free
copper material and is weld compatible with the outer conductor
2004 of the coaxial cable
The ferrule support ring or member 2024 includes a
cylindrically-shaped anvil support 2040 including: (i) a central
bore 2042 defining the opening 2032, (ii) a conically-shaped
concave surface 2044, (iii) an annular-shaped planar surface 2046
radially outboard of the conically-shaped concave surface 2044, and
(iv) an anti-rotation member 2048 projecting from the
annular-shaped planar surface 2046. With respect to the latter, the
anti-rotation member 2048 defines a first anti-rotation surface
2050 opposing a second anti-rotation surface 2030 formed along the
edges RL of the weld washer 2022. Additionally, the ferrule support
member 2024 includes an annular shoulder 2052 disposed about the
outer periphery 2054 of the ferrule support member 2024.
The ferrule cap or cap member 2026 includes an outer sleeve 2056
having an inwardly projecting annular flange or lip 2060 which, in
turn, defines the opening 2034 in the ferrule cap member 2026. The
outer sleeve 2056 is press fit over the outer periphery 2054 of the
ferrule support member 2024 such that the weld washer 2022 is
captured between the ferrule support and cap members 2024, 2026.
More specifically, the inwardly projecting flange or lip 2060
captures the outer edge 2062 of the weld washer 2022 (denoted by
dashed lines 2064) such that the opposing surface is pressed
against the planar annular surface 2046 of the ferrule support
member 2024. Furthermore, upon assembly, the anti-rotation surface
2030 (FIGS. 77 and 79) of the weld washer 2022 engages the
anti-rotation member 2050 of the anvil support, preventing the weld
washer 2022 from rotating about the elongate axis 2000A of the
jumper cable 2000.
It should also be appreciated that the openings 2032, 2034 are
substantially larger than the opening 2028 formed in the weld
washer 2022 to expose large face surfaces, i.e., inwardly of the
openings 2032, 2034, on each side of the weld washer 2022. One of
the face surfaces contacts the helical outer surface contour of the
outer conductor 2004 while the other face surface contacts the
folded/deformed end of the outer conductor 2004. These face
surfaces provide a large surface area for electrical contact with
the outer conductor 2004 of the coaxial cable 2000 to augment the
grounding contact between the outer conductor 2004 and the prepared
end 2020 of the cable 2000.
FIGS. 78-80 depict the prepared end of the coaxial cable 2000 in a
partially assembled state or condition. Therein, the weld washer
2022 threadably engages the helical outer surface contour 2036 of
the outer conductor 2004. The end 20004E of the outer conductor
2004 extends beyond or is "proud" relative to the opening 2028 of
the weld washer 2022 such that the end may be folded or deformed
over the edges of the opening 2028. The fold increases the
thickness of the edge along the washer opening 2028 to ensure that
the thickness is sufficient to enable a penetration weld along the
washer opening 2028. In one embodiment, the deformed edge increases
the thickness by at least a factor of two (2) to ensure a
sufficient weld thickness to penetration weld the edge of the outer
conductor 2004. In another embodiment, the deformed edge increases
the thickness by at least a factor of three (3). In the embodiment
described, the thickness of the deformed edge is nearly equivalent
to the thickness of the weld washer 2000 which, in the preferred
embodiment is within a range of between about twenty-five
thousandths inches (0.025'') to about one-hundred thousandths
inches (0.100'').
In FIG. 81, an enlarged view of the weld washer 2022 and ferrule
ring 2024 are depicted to view the planar outer surface 2044 and
the conical inboard surface 2046 of the ferrule ring 2024. The
outer sleeve 2056 of the ferrule cap 2026 aligns, and is
prepositioned for assembly, with a peripheral outer surface 2058 of
the ferrule support ring 2024. Furthermore, the root diameter RD of
the weld washer 2022 corresponds with a trough of the helical outer
surface contour 2036 of the outer conductor 2004.
FIGS. 82-84 depict the prepared end of the coaxial cable 2000 in an
assembled state or condition. Therein, the weld washer 2022 is
captured between the inwardly projecting lip 2060 of the ferrule
cap member 2026 and the support surface 2040 of the ferrule support
ring 2024. In FIG. 85, an enlarged view of the weld washer 2022 and
the ferrule support ring 2024 shows the deformed end 2004E in
greater detail. Therein, the end 2004E of outer conductor 2004 is
deformed over the edges of the washer opening 2028 by a conical
hammer or die 2066 (shown in phantom). Additionally, the weld
washer 2022 is deformed by the same conical hammer 2066, to form a
frustoconical shape. The frustocone defines a concave surface, or
reflection angle .degree..theta. relative to the orthogonal plane
VP3 normal to the elongate axis 2000A of the coaxial cable 2000. In
the described embodiment, the reflection angle .degree..theta. is
greater than at least about ten degrees (10.degree.) relative to
the orthogonal plane VP3. This geometry prevents reflected
penetration weld energy from adversely impacting, i.e., reflecting
back into, the energy source of the penetration weld. In the
illustrated embodiment, the penetration energy is reflected
inwardly toward the geometric center or the elongate axis 2000A of
the coaxial cable 2000.
In FIGS. 84 and 85, the penetration weld fuses the folded or
deformed edge 2004E of the outer conductor 2004 with the edges of
the weld washer opening 2028. In the described embodiment, the
penetration weld includes a plurality of contiguous spot welds 2070
equidistant from, and forming a circle about, the center 2000A of
the inner conductor 2002. In the described embodiment, the weld
washer 2022 and adaptor ring 2020 are inserted into a numerically
controlled, automated welding apparatus wherein the diameter of the
folded, deformed edge 2004E is measured and an initial weld
location, i.e., about the washer opening 2028, is established. A
control algorithm performs the penetration weld operation about the
face of the deformed edge 2004E about the three-hundred and sixty
degree (360.degree.) edge of the washer opening 2028.
Once the penetration weld operation is complete, a connector
coupler 2100 is attached or mounted to the peripheral outer surface
of the adaptor ring 2020. In the described embodiment, and
referring to FIGS. 86 and 87, the connector 2100 includes an outer
conductive sleeve 2104 which slides over and receives the prepared
end, i.e., the adaptor ring 2020 and weld washer 2022, of the
jumper cable 2000. The outer conductive sleeve 2104 supports a
threaded coupler 2110 about its outer periphery and receives a
centering member 2106 to support an inner conductor engager 2102.
The threaded coupler 2110 is operative to couple the connector 2100
a threaded interface port (not shown) while the centering member is
operative to provide an insulating support structure between the
inner conductor engager 2102 and the outer conductive sleeve 2104.
To secure the conductive sleeve 2104 to the adaptor ring 2020, a
locking cap 2114 is disposed over, and secures, the compliant outer
jacket 2010 of the coaxial cable 2000 to a recessed groove 2118
formed in an aft end of the conductive sleeve 2104. As such, a
biasing force is applied to the conductive sleeve 2104 causing the
sleeve 2104 to positively attach and lock to the adaptor ring
2020.
While already discussed in the detailed description, a method is
also disclosed for fabricating a jumper cable 2000 having a coaxial
cable connector 2100 attached to an end of the jumper cable 2000.
In a first step of the method, the weld washer 2022 is split along
a radial line RL to define a pair of opposed radial edges. Next,
the weld washer 2022 is stamped such that the radial edges are
out-of-plane and the washer 2022 defines a lead angle corresponding
to the lead angle .alpha. of the helical outer surface contour 2036
of the outer conductor 2004. In another step, the weld washer 2022
is threadably engaged onto the end 2004E of the helical outer
surface contour 2036 of the outer conductor 2004 such that the end
2004E thereof is proud relative to the washer opening 2028. Next,
the proud end is flared around the inner edges of the washer
opening 2028. And, in a final step, the flared end is penetration
welded to the weld washer 2022.
The embodiments described herein produce a jumper cable which
maintains substantially uniform impedance values through, and along
the length of, the coaxial cable 2000. Signal reflections are
minimized to optimize the efficacy of the transmitted signal and
mitigate passive intermodulation in the cable. Signal interference
is also reduced by the anti-rotation surfaces, i.e., weld washer
surface 2030 and ferrule ring surface 2050, which preventing
rotational motion between scuffing/friction interface surfaces,
such as between the inner conductor engager 2102 and the pin end
2012 of the inner conductor 2002 of the coaxial cable 2000.
Finally, the quantity of conductive copper is reduced to minimize
the fabrication cost of the jumper cable 2000.
It should be understood that various changes and modifications to
the embodiments described herein will be apparent to those skilled
in the art. Such changes and modifications can be made without
departing from the spirit and scope of the present disclosure and
without diminishing its intended advantages. It is therefore
intended that such changes and modifications be covered by the
appended claims.
Although several embodiments of the disclosure have been disclosed
in the foregoing specification, it is understood by those skilled
in the art that many modifications and other embodiments of the
disclosure will come to mind to which the disclosure pertains,
having the benefit of the teaching presented in the foregoing
description and associated drawings. It is thus understood that the
disclosure is not limited to the specific embodiments disclosed
herein above, and that many modifications and other embodiments are
intended to be included within the scope of the appended claims.
Moreover, although specific terms are employed herein, as well as
in the claims which follow, they are used only in a generic and
descriptive sense, and not for the purposes of limiting the present
disclosure, nor the claims which follow.
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